Schedule 80 PVC and CPVC

Schedule 40 PVC

Piping SystemsTechnical Manual

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Table of Contents

Introduction: PVC and CPVC Piping Systems ............................................................................................. 4Product Summary ................................................................................................................................................................. 4Material Data ..................................................................................................................................................................... 5-6

Engineering Data ......................................................................................................................................... 7Pressure Ratings ...............................................................................................................................................................7-9Water Hammer ................................................................................................................................................................. 9-11Temperature — Pressure Relationship ............................................................................................................................. 12Thermal Expansion and Contraction ........................................................................................................................... 13-17Friction — Loss Characteristics ...................................................................................................................................18-21

Installation Instructions ............................................................................................................................ 22Storage and Handling .........................................................................................................................................................22Solvent Welding ..............................................................................................................................................................22-27Threading ....................................................................................................................................................................... 28-29Flanging ...............................................................................................................................................................................30Above Ground Installation .............................................................................................................................................31-33Below Ground Installation ............................................................................................................................................ 34-36

Standards .................................................................................................................................................. 37ASTM ........................................................................................................................................................................... 37-38ASME/ANSI ...........................................................................................................................................................................38NSF/ANSI ..............................................................................................................................................................................38

Specifications ....................................................................................................................................... 39-41

IPS Socket Dimensions .............................................................................................................................. 42

Weld Lines in Molded Fittings .................................................................................................................... 43

Useful Charts and Conversions .......................................................................................................... 44-46

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Introduction: PVC and CPVC Piping Systems

Product SummaryThermoplastics PVC (Polyvinyl Chloride) and CPVC (Chlorinated Polyvinyl Chloride) are light, flexible, tough and provide exceptional corrosion resistance. Because of these and other properties of a high quality engineered thermo-plastic, the savings that can be realized in initial installation and continuing maintenance costs are substantial.

TemperaturePVC can handle temperatures up to 140˚F (60°C). CPVC handles temperatures up to 210˚F (99°C).

Chemical ResistancePVC and CPVC thermoplastics are highly resistant to acids, alkalis, alcohols and many other corrosive materials. Both materials are ideal for process piping installation and most service piping applica-tions. For details, please consult our Chemical Resistance Chart or contact your local sales represen-tative.

Maintenance Free ServicePVC and CPVC thermoplastics will not rust, scale, pit or corrode, nor are they subject to electroly-sis. You are assured many years of leak-free, maintenance-free service. For buried applications, PVC and CPVC are not affected by soil conditions or galvanic corrosion..

Painting is not required for indoor non-exposed installations. For outdoor installation where the piping may be exposed to significant sunlight, we recommend painting; two coats of a white or light-colored, water-base, outdoor latex paint provides added protection.

Lower Installed CostBoth PVC and CPVC have installed costs substantially lower than steel alloys or lined steel and are usually more competitive than carbon steel. Solvent cemented connections contribute to this lower installed cost while the much lighter weight (about one-sixth as much as steel) speeds and simplifies handling during installation.

Applications: Versatility and DependabilityPVC and CPVC fittings, pipe and valves have been found suitable for more than 50% of the corrosive and non-cor-rosive applications within the Chemical Process Industries. Vinyl piping systems have been sold into industrial applications for over 50 years. The establishment of strong industry standards and specifications, plus a third party certification through NSF, provides the specifying engineer, contractor and end user with a tested and accepted piping system to solve their corrosion problems.

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Material Data

Physical Properties of Rigid PVC and CPVC Thermoplastic Materials

The following table lists typical physical properties of PVC and CPVC thermoplastic materials.Variations may exist depending on specific compounds and product.

MechanicalProperties Unit PVC CPVC Remarks ASTM Test

Specific Gravity g/cm3 1.40 ± .02 1.55 ± .02 D-792

Tensile Strength @ 73°F PSI 7,200 8,000 Same in Circumferential Direction D-638

Modules of Elasticity Tensile @ 73°F PSI 430,000 360,000 Ratio of Stress on Bent Sample at Failure D-638

Compressive Strength @ 73°F PSI 9,500 10,100 D-695

Flexural Strength @ 73°F PSI 13,000 15,100 Tensile Stress/Strain on Bent Sample at Failure

D-790

Izod Impact @ 73°F Ft-Lbs/In of Notch

1.0 1.5 Impact Resistance of a Notched Sample to a Sharp Blow

D-256

Relative Hardness @ 73°F Durometer “D” Rockwell “R”

80 ± 3 110-120

— 119

Equivalent to Aluminum —

D-2240 D-785

ThermodynamicsProperties Unit PVC CPVC Remarks ASTM Test

Coefficient of Thermal Linear Expansion per °F

in/in/°F 2.8 x 10-5 3.4 x 10-5 D-696

Thermal Conductivity BTU/hr/ft2/ F/in 1.3 0.95 Average Specific Heat of 0-100°C C-177

Specific Heat CAL/g/°C 0.20-0.28 Ratio of Thermal Capacity to that of Water at 15°C

Maximum Operating Temperature °F 140 210 Pressure Rating is Directly Related to Temperature

Heat Distortion Temperature @ 264 PSI

°F 158 217 Thermal Vibration and Softening Occurs D-648

Decomposition Point °F 400+ 400+ Scorching by Carbonization and Dehydrochloration

FlammabilityProperties Unit PVC CPVC Remarks Test Method

Average Time of Burning sec. <5 <5 D-635

Average Extent of Burning mm <10 <10

Flame Spread Index <10 <10 E-162

Flame Spread 10-25 4-18 E-84

Flash Ignition °F 730 900 D-1929

Smoke Developed* 1000 285

Flammability (.062”) V-O V-O, 5VB 5VA

UL-94

Softening Starts, approx. °F 250 295

Material Become Viscous °F 350 395

Material Carbonizes °F 425 450

Limiting Oxygen Index (LOI) Vol. % 43 60 D-2863

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Note: This data is based on information supplied by the raw material manufacturers. It should be used as a general recommendation only and not as a guarantee of performance or longevity. The determination of the suitability of any material for a specific application is the responsibility of the end user.

OtherProperties Unit PVC CPVC Remarks ASTM Test

Water Absorption % +0.05 +0.03 @ 73°F +0.55 @ 212°F

Weight Gain in 24 Hours D-570

Poisson’s Ratio @ 73°F 0.38 0.27

ASTM Cell Classification 12454-B 23447-B D-1784

Industry Standard Color Dark Gray/ White

Medium Gray

NSF Potable Water Approved Yes Yes

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Engineering DataIn the engineering of thermoplastic piping systems, it is necessary to have not only a working knowledge of piping design but also an awareness of a number of the unique properties of thermoplastics.

In addition to chemical resistance, important factors to be considered in designing piping systems employing thermoplastics are1. Pressure ratings2. Water hammer3. Temperature-Pressure relationships4. Thermal expansion and contraction5. Friction-loss characteristics

These factors are considered in detail in this manual.

Pressure RatingDetermining pressure-stress pipe relationshipsISO Equation: The pressure rating of a pipe is deter-mined by the circumferential stress which results from internal pressure. The relationship between internal pressure, circumferential stress, wall thickness, and diameter is governed by an ISO equation. In various forms this equation is:

Long-Term Strength: To determine the long-term strength of thermoplastic pipe, lengths of pipe are capped at both ends (see Fig. 1-C) and subjected to various internal pressures, to produce circumferential stresses that will produce failure within 10 to 10,000 hours. The test is run according to ASTM D 1598 — Standard Test for Time Hydrostatic Pressure. The resulting failure points are used in a statistical analysis (outlined in ASTM D 2837) to determine the

Where: P = Internal Pressure, psi S = Circumferential Stress, psi t = Wall Thickness, in. DO = Outside Pipe Diameter, in. R = DO/t

P = 2S

= 2St

2S

= (DO)-1 R-1 DO-t P t

2S = R - 1 S =

P (R-1) P 2

Long-Term Strength Test per ASTM D-1598

Regression Curve — Stress/Time-to-Failure for PVC Type 1

Pipe test specimen per ASTM D-1598 for “Time-to-Failure of Plastic Pipe Under Long-Term Hydrostatic Pressure”

characteristic regression curve that represents the stress/time-to-failure relationship for the particular thermoplastic pipe compound under test. This curve is represented by the equation:

The regression curve may be plotted on a log-log paper, as shown in the Regression Curve figure below, and extrapolated from 10,000 to 100,000 hours (11.4 years). The stress at 100,000 hours is known as the Long Term Hydrostatic Strength (LTHS) for that particular thermo-plastic compound. From this (LTHS) the Hydrostatic Design Stress (HDS) is determined by applying the service factor multiplier, as shown on page 8.

Log T = a + b log S

Where:a and b are constants describing the slope and intercept of the curve, and T and S are time-to-failure and stress, respectively.

Figure 1-C

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Service Factor: The Hydrostatic Stress Committee of the Plastics Pipe Institute (PPI) has determined that a service (design) factor of one-half the Hydrostatic De-sign Basis would provide an adequate safety margin for use with water to ensure useful plastic-pipe service for a long period of time. While not stated in the standards, it is generally understood within the industry that this “service life” is a minimum of 50 years.

Accordingly, the standards for plastic pipe, using the 0.5 service factor, required that the pressure rating of the pipe be based upon this Hydrostatic Design Stress, again calculated with the ISO equation.

While early experience indicated that this service factor, or multiplier, of 0.5 provided adequate safety for many if not most uses, some experts felt that a more conserva-tive service factor of 0.4 would better compensate for water hammer pressure surges, as well as for slight manufacturing variations and damage suffered during installation.

The PPI has issued a statement recommending this 0.4 service factor. This is equivalent to recommending that the pressure rating of the pipe should equal 1.25 times the system design pressure for any particular instal-lation. Based upon this calculation, many thousands of miles of thermoplastic pipe have been installed in the United States without failure.

It is best to consider the actual surge conditions, as outlined later in this section. In addition, reductions in working pressure should be considered when handling aggressive chemical solutions and in high-temperature service.

Numerical relationships for service factors and design stresses of PVC and CPVC are shown in the table below.

Service Factors and Hydrostatic Design Stress (HDS)*(Hydrostatic Design Basis equal 4000 psi) (27.6 MPa)

Service Factor HDS

0.5 2000 psi (13.8 MPa)

0.4 1600 psi (11 MPa)

*Material: PVC Type I & CPVC

Maximum Pressures: The pressure ratings of thermo-plastic pipe represent the maximum allowable operat-ing pressure within a piping system for water at 73°F (22.8°C) based upon a service factor of 0.5.

Maximum Pressure Rating for Schedule 80 PVC/CPVC Pipe at 73°FSize PSI Bar

½” 848 57.7

¾” 688 46.8

1” 630 42.9

1¼” 520 35.4

1½” 471 32.0

2” 404 27.5

2½” 425 28.9

3” 375 25.5

4” 324 22.0

6” 279 19.0

8” 246 16.7

10” 234 15.9

12” 228 15.5

External Pressures — Collapse RatingThermoplastic pipe is frequently specified for situations where uniform external pressures are applied to the pipe, such as underwater applications. In these appli-cations, the collapse rating of the pipe determines the maximum permissible pressure differential between external and internal pressures. The basic formulas for collapsing external pressure applied uniformly to a long pipe are:

1. For thick wall pipe where collapse is caused by elastic instability of the pipe wall:

Pc = Ó (DO2 - Di2)

2DO2

2. For thin wall pipe where collapse is caused by elastic instability of the pipe wall:

Pc = 2cE ( t )3

1-v2 Dm

Where: Pc = Collapse Pressure (external minus internal pressure),

psi Ó = Compressive Strength, psi v = Poisson’s Ratio E = Modulus of Elasticity, psi DO = Outside Pipe Diameter, in. Dm = Mean Pipe Diameter, in. Di = Inside Pipe Diameter, in. t = Wall Thickness, in. c = Out of Roundness Factor, Approximately 0.66

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The result is a high momentary pressure surge called water hammer. The five factors that determine the severity of water hammer are:

1. Velocity (The primary factor in excessive water hammer; see

discussion of “Velocity” and “Safety Factor” below)2. Modulus of elasticity of pipe material3. Inside diameter of pipe4. Wall thickness of pipe5. Valve closing time

Maximum pressure surges caused by water hammer can be calculated by using the equation below. This surge pressure should be added to the existing line pressure to arrive at a maximum operating pressure figure.

Calculated surge pressure, which assumes instanta-neous valve closure, can be calculated for any material using the values for E (Modulus of Elasticity).

However, to keep water hammer pressures within rea-sonable limits, it is common practice to design valves for closure times considerably greater than 2L/c.

Short Term Collapse Pressure in psi at 73°F½” ¾” 1” 1¼” 1½” 2” 3” 4” 6” 8” 10” 12”

Schedule 40 PVC

2095 1108 900 494 358 211 180 109 54 39 27 29

Schedule 80 PVC/CPVC

2772 2403 2258 1389 927 632 521 335 215 147 126 117

Note: These are short term ratings; long term should be reduced by ¹/3 to ½ of the short term ratings.

Choice of Formula: By using formula 2 on thick wall pipe an excessively large pressure will be obtained. It is therefore necessary to calculate, for a given pipe size, the collapse pressure using both formulas and use the lower value as a guide to safe working pressure. See the following table for short term collapse pressures at 73°F. For long term loading conditions, appropriate long term data should be used.

Vacuum ServiceAs implied by the collapse rating, thermoplastic pipe is suitable for vacuum or negative pressure conditions that are found in many piping applications.

Laboratory tests have been conducted on Schedule 80 PVC pipe to determine performance under vacuum at temperatures above recommended operating condi-tions. A 6” pipe showed slight deformation at 165°F and 20 inches of mercury. Above this temperature, failure occurred due to thread deformation.

Conclusion: All sizes of Schedule 80 PVC and CPVC thermoplastic pipe are suitable for vacuum service up to 140°F and 30 inches of mercury. In addition, CPVC may be used up to 210°F. Solvent cemented joints are required for vacuum applications.

Water HammerSurge pressures due to water hammer are a major factor contributing to pipe failure in liquid transmission systems. A column of moving fluid within a pipeline, owing to its mass and velocity, contains stored energy. Since liquids are essentially incompressible, this energy cannot be absorbed by the fluid when a valve is sud-denly closed.

Tc > 2L c

Where: Tc = Valve Closure Time, second L = Length of Pipe Run, feet c = Sonic Velocity of the Pressure Wave = 4720 ft/second

Ps = V ( E t 3960 )½

E t + 3 x 105Di

Where: Ps = Surge Pressure, in psi V = Liquid Velocity, in feet per second Di = Inside Pipe Diameter, inch E = Modulus of Elasticity of Pipe Material, psi t = Wall Thickness, inch

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VelocityThermoplastic piping has been successfully installed in systems with a water velocity in excess of 10 feet per second. Thermoplastic pipe is not subject to erosion caused by high velocities and turbulent flow and in this respect is superior to metal piping systems, particularly where corrosive or chemically aggressive fluids are involved. The accepted industry position is that while the maximum safe water velocity in a thermoplastic piping system depends on the specific details of the system and the operating conditions, five feet per sec-ond is considered safe. Higher velocities may be used in systems where the operating characteristics of the valves and pumps are known and sudden changes in flow velocity can be controlled. It is important that the total pressure in the system at any time (operating plus surge or water hammer) not exceed 150 percent of the pressure rating for the system.

Safety FactorSince the duration of any pressure surges due to water hammer is extremely short — seconds, or more likely, fractions of a second — the calculations used in deter-mining the Safety Factor, the maximum fiber stress due to internal pressure must be compared to some very short-term strength value. Referring to the “Regres-sion Curve” chart on page 7, it shows that the failure stress for very short time periods is very high when compared to the Hydrostatic Design Stress.

Using this premise, the calculation of Safety Factor may be based, very conservatively, on the 20-second strength value given in the “Regression Curve” chart (page 7) — 8470 psi for PVC Type I.

A sample calculation is shown below, based upon the listed criteria:Pipe = 1¼” Schedule 80 PVC I O.D. = 1.660; Wall = 0.191HDS = 2000 psi

The calculated surge pressure for 1¼” Schedule 80 PVC pipe at a velocity of 1 ft/sec. is 26.2 psi/ft/sec. (see next page)

Water Velocity = 5 feet per secondStatic Pressure in System = 300 psiTotal System Pressure = Total Static + Surge PressurePt = P + PS = 300 + 5 x 26.2 = 431.0 psi

Maximum circumferential stress is calculated from a variation of the ISO Equation:

S = Pt (Do-t) = 431 (1.660 - 191) = 1657.4 2t 2 x 191

Safety Factor = 20-second strength Maximum stress

= 8470 = 5.11 1657

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The “Safety Factors vs. Service Factors” table (see below) gives the results of Safety Factor calculations based upon Service Factors of 0.5 and 0.4 for the 1¼” PVC I Schedule 80 pipe of the example shown on page 10 using the full pressure rating calculated from the listed Hydrostatic Design Stress. In each case, the Hydrostatic Design Basis = 4000 psi, and the water velocity = 5 feet per second.

Safety Factors vs. Service Factors — PVC Type I Thermoplastic PipePipe Class Service

FactorHDS, psi Pressure

Rating psiSurge Pressure at 5 ft./sec.

Maximum Pressure psi

Maximum Stress psi

Safety Factor

1¼” Sch. 80 0.5 2000 520 131.0 651.0 2503.5 3.38

1¼” Sch. 80 0.4 1600 416 131.0 547.0 2103.5 4.03

Pressure Rating values are for PVC I pipe, and for most sizes are calculated from the experimentally determined Long Term Strength of PVC I extru-sion compounds. Because molding compounds may differ in Long Term Strength and elevated temperature properties from pipe compounds, piping systems consisting of extruded pipe and molded fittings may have lower pressure ratings than those shown here, particularly at the higher tempera-tures. Caution should be exercised in design of systems operating above 100°F.

Surge Pressure, Ps in psi at 73°Fwater velocity (ft./sec.)

½” ¾” 1” 1¼” 1½” 2” 3” 4” 6” 8” 10” 12”

Schedule 40 PVC

1 27.9 25.3 24.4 22.2 21.1 19.3 18.9 17.4 15.5 14.6 13.9 13.4

2 55.8 50.6 48.8 44.4 42.2 38.6 37.8 34.8 31.0 29.2 27.8 26.8

3 83.7 75.9 73.2 66.6 63.3 57.9 56.7 52.2 46.5 43.8 41.7 40.2

4 111.6 101.2 97.6 88.8 84.4 77.2 75.6 69.6 62.0 58.4 55.6 53.6

5 139.5 126.5 122.0 111.0 105.5 96.5 94.5 87.0 77.5 73.0 69.5 67.0

6 167.4 151.8 146.4 133.2 126.6 115.8 113.4 104.4 93.0 87.6 83.4 80.4

Schedule 80 PVC/CPVC

1 32.9 29.9 28.7 26.2 25.0 23.2 22.4 20.9 19.4 18.3 17.3 17.6

2 65.6 59.8 57.4 52.4 50.0 46.4 44.8 41.8 38.8 36.6 35.6 35.2

3 98.7 89.7 86.1 78.6 75.0 69.6 67.2 62.7 58.2 59.9 53.4 52.8

4 131.6 119.6 114.8 104.8 107.0 92.8 89.6 83.6 77.6 73.2 71.2 70.4

5 164.5 149.5 143.5 131.0 125.0 116.3 112.0 104.5 97.0 91.5 89.0 88.0

6 197.4 179.4 172.2 157.2 150.0 133.2 134.4 125.4 116.4 109.8 106.8 105.6

Comparing Safety Factors for this 1¼” Schedule 80 pipe at different Service Factors, it is should be noted that changing from a Service Factor of 0.5 to a more conser-vative 0.4 increases the Safety Factor only by 16%.

Cyclic Fatigue in Vinyl Piping SystemsWhen discussing water hammer or pressure surge in a piping systems, one should also be aware of a failure mode termed “Cyclic Fatigue.” A piping system that has frequent and significant changes in flow conditions or pressure, creating a fluctuating surge, can have an ef-fect on the structural integrity of a thermoplastic fitting. This condition has been observed in golf course irriga-tion systems that experience tens of thousands of water pressure surges over the course of a year. The resul-tant failure from cyclic fatigue is very similar in ap-

pearance to long-term static failure and it may be very difficult to ascertain the exact cause of such failures.

However, the design engineer should consider this phenomenon when designing a GF Piping System with frequent pressure changes, particularly if the surge pressure exceeds 50% of the systems working pres-sure. Based on some testing by Keller-Bliesener En-gineering, the engineer may want to consider devaluing the fitting by 40% from the published pipe burst pres-sure. Keeping the flow velocity to 5 fps or less will also have an effect on pressure surges. Other consider-ations would be to use actuated valves that can be set to provide a slow opening or to install “soft start” pumps, as both of these will limit the water hammer and the resultant pressure surges.

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Pressure ratings for thermoplastic pipe are generally determined using water at room temperature (73°F). As the system temperature increases, the thermo-plastic pipe becomes more ductile, increases in impact strength and decreases in tensile strength. The pres-sure ratings of thermoplastic pipe must, therefore, be decreased accordingly.

The effects of temperature have been exhaustively studied and correction (derating) factors developed for each thermoplastic piping material. To determine the maximum operating pressure at any given temperature, multiply the pressure rating for the pipe size and type found in the following table by the temperature derating factor (f).

Temperature-Pressure Relationship

Solvent-Welded Pressure Rating vs. Service Temperature — PVC and CPVC

Nom

. Siz

e (in

ch)

D O

utsi

de D

ia

t Wal

l

DR

= D

/t

P

73˚F 90˚F 100˚F 110˚F 120˚F 130˚F 140˚F 150˚F 160˚F 180˚F 200˚F 210˚F

PVC

f=1.00

s=2000

CPVC

f=1.00

s=2000

PVC

f=0.75

s=1500

CPVC

f=0.92

s=1840

PVC

f=0.62

s=1240

CPVC

f=0.85

s=1700

PVC

f=0.50

s=1000

CPVC

f=0.77

s=1540

PVC

f=0.40

s=800

CPVC

f=0.70

s=1400

PVC

f=0.30

s=600

CPVC

f=0.62

s=1240

PVC

f=0.22

s=440

CPVC

f=0.50

s=1000

CPVC

f=0.47

s=940

CPVC

f=0.40

s=800

CPVC

f=0.25

s=500

CPVC

f=0.18

s=400

CPVC

f=0.16

s=320

½ 0.84 0.15 5.71 848 848 636 780 526 721 424 653 339 594 254 526 187 466 399 339 212 153 136

¾ 1.05 0.15 6.82 688 688 516 633 426 585 344 530 275 482 206 427 151 378 323 275 172 124 110

1 1.32 0.18 7.35 630 630 473 580 390 536 315 485 252 441 189 391 139 347 296 252 158 113 101

1¼ 1.66 0.19 8.69 520 520 390 478 322 442 260 400 208 364 156 322 114 286 244 208 130 94 83

1½ 1.90 0.20 9.50 471 471 353 433 292 400 236 363 188 330 141 292 104 259 221 188 118 85 75

2 2.38 0.22 10.89 404 404 303 372 251 343 202 311 162 283 121 250 89 222 190 162 101 73 65

2½ 2.88 0.28 10.42 425 425 319 391 263 361 213 327 170 298 128 264 94 234 200 170 106 77 68

3 3.50 0.30 11.67 375 375 281 345 233 319 188 289 150 263 113 233 83 206 176 150 94 68 60

4 4.50 0.34 13.35 324 324 243 298 201 275 162 249 130 227 97 201 71 178 152 130 81 58 52

6 6.63 0.43 16.34 279 279 209 257 173 237 140 215 112 195 84 173 61 153 131 112 70 50 45

8 8.63 0.50 17.25 246 246 185 226 153 209 123 189 98 172 74 153 54 135 116 98 62 44 39

10 10.75 0.59 18.13 234 234 175 215 145 199 117 180 94 164 70 145 51 129 110 94 59 42 37

12 12.75 0.69 18.56 228 228 171 210 141 194 114 176 91 160 68 141 51 125 107 91 57 41 36

P = 2St = 2S = P73°Ff D-t DR-1P = Pressure rating of pipe at service temperatures (psi)S = Hydrostatic design stress (psi)D = Outside diameter of pipe (inches)

1) Figures for pressure rating at 73°F are rounded off from actual calculated values. Pressure ratings for other temperatures are calculated from 73°F values.

2) Pressure rating values are for PVC (12454-B) and CPVC (23447-B) pipe and for most sizes are calculated from the experimentally determined long-term strength of PVC1 and CPVC extrusion compounds. Because molding compounds may differ in long-term strength and elevated temperature properties from pipe compounds, piping systems consisting of extruded pipe and molded fittings may have lower pressure ratings than those shown here, particularly at the higher temperatures. Caution should be exercised when designing PVC systems operating above 100°F and CPVC systems operating above 180°F.

3) The pressure ratings given are for solvent-cemented systems. When adding valves, flanges or other components, the system must be derated to the rating of the lowest component. (Pressure ratings: molded or cut threads are rated at 50% of solvent-cemented systems; flanges and unions are 150 psi; for valves, see manufacturer’s recommendation.)

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Thermal Expansion and Contraction

Thermoplastics exhibit a relatively high coefficient of thermal expansion — as much as ten times that of steel. When designing plastic piping systems, expansion of long runs must be considered. Installation temperature versus working temperature or summer to winter extremes must be considered.

Linear Expansion and Contraction

Coefficient of Thermal Linear Expansion

PVC = 2.8 x 10-5 in/in/°FCPVC = 3.4 x 10-5 in/in/°F

To Calculate:∆L = Change in pipe length due

to thermal changes.

L = Straight runs of pipe with no changes in direction.

Y = Coefficient of thermal expansion (see above).

∆T = maximum change in temperature between installation and operation (T MAX. - T. MIN.)

∆L = Y x L x ∆T

Example:• A system has 350 feet

(4,200”) of straight run (L) with no direction change.

• Pipe material is CPVC. Coefficient (Y) is 3.4 x 10-5 (0.000034”).

• Pipe is installed at an ambient temperature of 60°F. Maximum anticipated operating temperature is 140°F. The difference (∆T) is 80°F.

∆L = 0.000034 x 4200 x 80

∆L = 11.4” of linear expansion in 350 ft. in pipe.

Change in Pipe Length (Inches/Foot)

180

170

160

150

140

130

120

110

100

90

80

70

60

50

40

30

20

10

0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10

PV

C

CPVC

T

L

14

1. Offsets: Most piping systems have occasional changes in direction which will allow the thermally induced length changes to be taken up in offsets of the pipe beyond the bends. Where this method is employed, the pipe must be able to float except at anchor points.

2. Expansion Joints: Piston type expansion joints can be an effective means of compensating for expansion or contraction when the system has critical dimensions with no room for movement, or where appearance is important. It is important to follow the manufacturers recommendations regarding support, anchoring and the proper setting of the expansion joint.

Tables for expansion loops, offsets and expansion joints have been generated for elevated temperatures as noted be-neath each table. If the change in temperature and working temperatures are lower than those used to derive expansion loop and offset tables, the figures will be conservative. These tables can be generated for any temperature and expansion by using the following equations and the modulus of elasticity and working stress at the given temperature.

Assume the pipe to be a cantilevered beam.

For a beam, the bending stress can be calculated by

“Equation 1:”

For application to pipe, the maximum stress occurs where C equals the radius of the pipe. Substituting the radius for C and rearranging the equation to solve for the Moment is

shown in “Equation 2:”

M = 2 * S * I ODWhere: OD = Pipe Outer Diamter (in) C = Radius of pipe = OD/2 (in)

M = 6 * E * I * y DPL2

Where: E = Modulus of Elasticity (psi) y = imposed deflection (in) DPL = deflected pipe length (in)

By equating “2” and “3,” the equation for the deflected beam length (DPL) can be solved:

After determining the proper allowable stress, “Equation 4” gives an estimate of the minimum deflected pipe length (DPL) required to sustain a piping thermal movement of length y normal to the piping.

“Equation 4” can be used to calculate the minimum deflected pipe length for expansion loops, offsets and change of direc-tions:

Note: In some cases, a stress intensification factor (i) is added as shown in “Equation 5.” The stress intensifica-tion factor is used as a safety factor to account for the effect of localized stresses on piping under repetitive loading. For example, the stress intensification factor for socket welded joints is 1.3 and for threaded joints the factor is 2.3 per ANSI/ASME B31.3, B31.4, B31.5 and B31.8 codes.

The free body diagram which most closely approximates the deflected pipe in an expansion loop, offset or change in direc-tion is shown in Figure A (see page 16). This is not a cantile-ver beam but rather a guided cantilever beam. For a guided cantilever, the moment induced by an imposed deflection is calculated by “Equation 3:”

S = M * C IWhere: S = Stress (psi) M = Moment (in lbs.) C = Distance from neutral axis (in.) I = Moment of Inertia (in4)

2 * S * I = 6 * E * I * y OD DPL2

“Equation 4:”

DPL = √3 * E * OD * y S

“Equation 5:”

DPL = √3 * E * OD * y * i S

15

“Equation 6” is used to calculate the change in length caused by thermal expansion:

∆L = 12 * e * L * ∆T

Where: ∆L = Change in length (in) e = Coefficient of Thermal Expansion (in/in °F) L = Length of Straight Pipe Run (ft) ∆T = Change in Temperature (°F)

For the expansion loop, shown in Figure B (see page 16), the imposed deflection is one-half the change in length as repre-

sented in “Equation 7”:

“Equation 4” can be modified to replace the deflection (y) with equation 6 for the change in length (∆L) according to the relationship shown in “Equation 7.”

For the offset shown in Figure C (see page 17) and the change in direction shown in Figure D (page 17), the imposed deflec-tion is equal to the change in length caused by thermal expansion.

“Equation 9:”y = ∆L

“Equation 4” can be modified to replace the deflection (y) with “Equation 6” for the change in length ∆L according to the relationship shown in “Equation 9.”

Note: In the tables to follow (see page 16), we have chosen to use values for the allowable stress (S) and the modulus of elasticity (E) at the upper temperature limit.

Many calculations (in other manufacturers’ literature) are based on the allowable stress and the modulus of elastic-ity at ambient conditions. This simplification is allowed because for most plastics (S) and (E) vary with tempera-ture at approximately the same rate.

y = ∆L 2

“Equation 8:” Expansion Loop

DPL = 4.243 * √E * OD * e * L * ∆T SWhere: DPL = Deflected Pipe Length (in) E = Modulus of Elasticity (psi) OD = Pipe Outer Diameter (in) e = Coefficients of Thermal Expansion (in/in °F) L = Length of Straight Pipe Run (ft) ∆T = Change in Temperature (°F) S = Allowable Stress (psi)

“Equation 10:” Offsets and Change of Direction

DPL = 6.0 * √E * OD * e * L * ∆T S

Where: DPL = Deflected Pipe Length (in) E = Modulus of Elasticity (psi) OD = Pipe Outer Diameter (in) e = Coefficient of Thermal Expansion (in/in °F) L = Length of Straight Pipe Run (ft) ∆T = Change in Temperature (°F) S = Allowable Stress (psi)

“Equation 11” Piston Type Expansion Joints

Px = Tmax – Tamb x ∆L Tmax – Tmin

Where:Px = Piston Installation PositionTmax = Maximum temperatureTmin = Minimum Temperature Tamb = Ambient Temperature∆L = Length of Expansion Joint (6” or 12”)

16

PVC Expansion Loops

PVCLength of Run (feet)

10 20 30 40 50 60 70 80 90 100

Pipe Size (in.)

O.D. of Pipe (in.)

Minimum Deflected Pipe Length (DPL) (inches)

½ 0.840 11 15 19 22 24 27 29 31 32 34

¾ 1.050 12 17 21 24 27 30 32 34 36 38

1 1.315 14 19 23 27 30 33 36 38 41 43

1¼ 1.660 15 22 26 30 34 37 40 43 46 48

1½ 1.900 16 23 28 33 36 40 43 46 49 51

2 2.375 18 26 32 36 41 45 48 51 55 58

3 3.500 22 31 38 44 49 54 58 62 66 70

4 4.500 25 35 43 50 56 61 66 71 75 79

6 6.625 30 43 53 61 68 74 80 86 91 96

8 8.625 35 49 60 69 78 85 92 98 104 110

10 10.750 39 55 67 77 87 95 102 110 116 122

12 12.750 42 60 73 84 94 103 112 119 127 133

Figure A: Guided Cantilever Beam Figure B: Expansion Loop

PVC Offsets and Change of Directions

PVCLength of Run (feet)

10 20 30 40 50 60 70 80 90 100

Pipe Size (in.)

O.D. of Pipe (in.)

Minimum Deflected Pipe Length (DPL) (inches)

½ 0.840 15 22 27 31 34 37 41 43 46 48

¾ 1.050 17 24 30 34 38 42 45 48 51 54

1 1.315 19 27 33 38 43 47 51 54 57 61

1¼ 1.660 22 30 37 43 48 53 57 61 65 68

1½ 1.900 23 33 40 46 51 56 61 65 69 73

2 2.375 26 36 45 51 58 63 68 73 77 81

3 3.500 31 44 54 62 70 77 83 88 94 99

4 4.500 35 50 61 71 79 87 94 100 106 112

6 6.625 43 61 74 86 96 105 114 122 129 136

8 8.625 49 69 85 98 110 120 130 139 147 155

10 10.750 55 77 95 110 122 134 145 155 164 173

12 12.750 60 84 103 119 133 146 158 169 179 189

17

Figure C: Expansion Offset Figure D: Change of Direction

CPVC Expansion Loops

CPVCLength of Run (feet)

10 20 30 40 50 60 70 80 90 100

Pipe Size (in.)

O.D. of Pipe (in.)

Minimum Deflected Pipe Length (DPL) (inches)

½ 0.840 15 21 26 30 33 36 39 42 44 47

¾ 1.050 17 23 29 33 37 40 44 47 50 52

1 1.315 18 26 32 37 41 45 49 52 55 58

1¼ 1.660 21 29 36 42 46 51 55 59 62 66

1½ 1.900 22 31 39 44 50 54 59 63 67 70

2 2.375 25 35 43 50 56 61 66 70 75 79

3 3.500 30 43 52 60 67 71 80 85 91 95

4 4.500 34 48 59 68 77 84 91 97 103 108

6 6.625 42 59 72 83 93 102 110 117 125 131

8 8.625 47 67 82 95 106 116 125 134 142 150

10 10.750 53 75 92 106 118 130 140 150 159 167

12 12.750 58 81 100 115 129 141 152 163 173 182

CPVC Offsets and Change of Directions

CPVCLength of Run (feet)

10 20 30 40 50 60 70 80 90 100

Pipe Size (in.)

O.D. of Pipe (in.)

Minimum Deflected Pipe Length (DPL) (inches)

½ 0.840 21 30 36 42 47 51 55 59 63 66

¾ 1.050 23 33 40 47 22 57 62 66 70 74

1 1.315 26 37 45 52 58 61 69 74 78 83

1¼ 1.660 29 42 51 59 66 72 78 86 88 93

1½ 1.900 31 44 54 63 70 77 83 89 94 99

2 2.375 35 50 61 70 79 86 93 99 105 111

3 3.500 43 60 74 85 95 105 113 121 128 135

4 4.500 48 68 84 97 108 119 128 137 145 153

6 6.625 59 53 102 117 131 144 155 166 176 186

8 8.625 67 95 116 134 150 164 177 189 201 212

10 10.750 75 106 130 150 167 183 198 212 224 237

12 12.750 81 115 141 163 182 200 216 230 244 258

18

Friction-Loss Characteristics

Introduction A major advantage of thermoplastic pipe is its excep-tionally smooth inside surface area, which reduces friction loss compared to other materials.

Friction loss in plastic pipe remains constant over extended periods of time, in contrast to many traditional materials where the value of the Hazen and Williams C factor (constant for inside roughness) decreases with time. As a result, the flow capacity of thermoplastics is greater under fully turbulent flow conditions like those encountered in water service.

C Factors Tests made both with new pipe and pipe that had been in service revealed C factor values for plastic pipe between 160 and 165. Thus, the factor of 150 recom-mended for water in Equation 12 is on the conservative side. On the other hand, the C factor for metallic pipe varies from 65 to 125, depending upon age and interior roughening. A benefit with plastic piping systems is that it is often possible to achieve the desired flow rate using a smaller diameter pipe, resulting in less initial cost for pipe, valves, fitting and pumps, and still main-tain the same or even lower friction losses. A longer term benefit would be the resultant savings in energy required to operate the system.

f = 0.2083 (100)1.852 x g

1.852

C Di4.8655

= 0.0983 q1.852 for C = 150 Di4.8655

P = 4335f

Where:f = Friction Head in ft. of Water per 100 ft. of PipeP = Pressure Loss in psi per 100 ft. of PipeDi = Inside Pipe Diameter, in.g = Flow Rate in U.S. gal./min.C = Constant for Inside Roughness

(C equals 150 for thermoplastics)

Hazen and Williams FormulaThe head losses resulting from various water flow rates in plastic piping may be calculated by means of the Hazen and Williams formula:

“Equation 12:”

19

Friction Loss — Schedule 40 PipeCarrying capacity, friction loss and flow data for Schedule 40 thermoplastic pipe are presented in tabular form in the table below. This table is applicable to pipe made of any of the thermoplastic piping materials as all have equally smooth interior surfaces.

Carrying Capacity and Friction Loss — Schedule 40 Thermoplastics PipeIndependent variables: Gallons per minute and nominal pipe size O.D. (Min. I.D.)Dependent variables: Velocity, friction head and pressure drop per 100 feet of pipe, interior smooth.

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½ in. ¾ in. 1 in. 1¼ in. 1½ in. 2 in. 3 in.1 1.13 2.08 0.90 0.63 0.51 0.222 2.26 4.16 1.80 1.26 1.02 0.44 0.77 0.55 0.24 0.44 0.14 0.06 0.33 0.07 0.035 5.64 23.44 10.15 3.16 5.73 2.48 1.93 1.72 0.75 1.11 0.44 0.19 0.81 0.22 0.09 0.49 0.066 0.029 0.03 0.015 0.0077 7.90 43.06 18.64 4.43 10.52 4.56 2.72 3.17 1.37 1.55 0.81 0.35 1.13 0.38 0.17 0.69 0.11 0.048 0.49 0.021 0.00910 11.28 82.02 35.51 6.32 20.04 8.68 3.86 6.02 2.61 2.21 1.55 0.67 1.62 0.72 0.31 0.98 0.21 0.091 0.68 0.03 0.01315 4 in. 9.48 42.46 18.39 5.79 12.77 5.53 3.31 3.28 1.42 2.42 1.53 0.66 1.46 0.45 0.19 1.03 0.07 0.03020 0.51 0.03 0.013 12.65 72.34 32.32 7.72 21.75 9.42 4.42 5.59 2.42 3.23 2.61 1.13 1.95 0.76 0.33 1.37 0.11 0.04825 0.64 0.04 0.017 5 in. 9.65 32.88 14.22 5.52 8.45 3.66 4.04 3.95 1.71 2.44 1.15 0.50 1.71 0.17 0.07430 0.77 0.06 0.026 0.49 0.02 0.009 11.58 46.08 19.95 6.63 11.85 5.13 4.85 5.53 2.39 2.93 1.62 0.70 2.05 0.23 0.1035 0.89 0.08 0.035 0.57 0.03 0.013 7.73 15.76 6.82 5.66 7.36 3.19 3.41 2.15 0.93 2.39 0.31 0.1340 1.02 0.11 0.048 0.65 0.03 0.013 8.84 20.18 8.74 6.47 9.43 4.08 3.90 2.75 1.19 2.73 0.40 0.1745 1.15 0.13 0.056 0.73 0.04 0.017 6 in. 9.94 25.10 10.87 7.27 11.73 5.80 4.39 3.43 1.49 3.08 0.50 0.2250 1.28 0.16 0.069 0.81 0.05 0.022 0.56 0.02 0.009 11.05 30.51 13.21 8.08 14.25 6.17 4.88 4.16 1.80 3.42 0.60 0.2660 1.53 0.22 0.095 0.97 0.07 0.030 0.67 0.03 0.013 9.70 19.98 8.65 5.85 5.84 2.53 4.10 0.85 0.3770 1.79 0.30 0.13 1.14 0.10 0.043 0.79 0.04 0.017 6.83 7.76 3.36 4.79 1.13 0.4975 1.92 0.34 0.15 1.22 0.11 0.048 0.84 0.05 0.022 7.32 8.82 3.82 5.13 1.28 0.5580 2.05 0.38 0.16 1.30 0.13 0.056 0.90 0.05 0.022 8 in. 7.80 9.94 4.30 5.47 1.44 0.6290 2.30 0.47 0.20 1.46 0.16 0.069 1.01 0.06 0.026 8.78 12.37 5.36 6.15 1.80 0.78100 2.56 0.58 0.25 1.62 0.19 0.082 1.12 0.08 0.035 0.65 0.03 0.012 9.75 15.03 6.51 6.84 2.18 0.94125 3.20 0.88 0.38 2.03 0.29 0.125 1.41 0.12 0.052 0.81 0.035 0.015 10 in. 8.55 3.31 1.43150 3.84 1.22 0.53 2.44 0.40 0.17 1.69 0.16 0.069 0.97 0.04 0.017 10.26 4.63 2.00175 4.48 1.63 0.71 2.84 0.54 0.235 1.97 0.22 0.096 1.14 0.055 0.024 6.16 2.67200 5.11 2.08 0.90 3.25 0.69 0.30 2.25 0.28 0.12 1.30 0.07 0.030 0.82 0.027 0.012 12 in. 7.88 3.41250 6.40 3.15 1.36 4.06 1.05 0.45 2.81 0.43 0.19 1.63 0.11 0.048 1.03 0.035 0.015 11.93 5.17300 7.67 4.41 1.91 4.87 1.46 0.63 3.37 0.60 0.26 1.94 0.16 0.069 1.23 0.05 0.022350 8.95 5.87 2.55 5.69 1.95 0.85 3.94 0.79 0.34 2.27 0.21 0.091 1.44 0.065 0.028 1.01 0.027 0.012400 10.23 7.52 3.26 6.50 2.49 1.08 4.49 1.01 0.44 2.59 0.27 0.12 1.64 0.09 0.039 1.16 0.04 0.017450 7.31 3.09 1.34 5.06 1.26 0.55 2.92 0.33 0.14 1.85 0.11 0.048 1.30 0.05 0.022500 8.12 3.76 1.63 5.62 1.53 0.66 3.24 0.40 0.17 2.05 0.13 0.056 1.45 0.06 0.026750 8.43 3.25 1.41 4.86 0.85 0.37 3.08 0.28 0.12 2.17 0.12 0.0521000 11.24 5.54 2.40 6.48 1.45 0.63 4.11 0.48 0.21 2.89 0.20 0.0871250 8.11 2.20 0.95 5.14 0.73 0.32 3.62 0.31 0.131500 9.72 3.07 1.33 6.16 1.01 0.44 4.34 0.43 0.192000 8.21 1.72 0.74 5.78 0.73 0.322500 10.27 2.61 1.13 7.23 1.11 0.49

20

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½” ¾” 1” 1¼ “ 1½” 2” 2½” 3”1 1.43 4.02 1.74 0.74 0.86 0.372 2.95 8.03 3.48 1.57 1.72 0.74 0.94 0.88 0.33 0.52 0.21 0.09 0.38 0.10 0.0415 7.89 45.23 19.59 3.92 9.67 4.19 2.34 2.78 1.19 1.30 0.66 0.29 0.94 0.30 0.126 0.56 0.10 0.040 0.39 0.05 0.022 0.25 0.02 0.0097 10.34 83.09 35.97 5.49 17.76 7.59 3.23 5.04 2.19 1.82 1.21 0.53 1.32 0.55 0.24 0.78 0.15 0.088 0.54 0.07 0.032 0.35 0.023 0.01310 7.84 33.84 14.65 4.68 9.61 4.16 2.60 2.30 1.00 1.88 1.04 0.45 1.12 0.29 0.13 0.78 0.12 0.052 0.50 0.04 0.01715 4 in. 11.76 71.70 31.05 7.01 20.36 8.82 3.90 4.87 2.11 2.81 2.20 0.95 1.63 0.62 0.27 1.17 0.26 0.11 0.75 0.09 0.03920 0.57 0.04 0.017 9.35 34.68 15.02 5.20 8.30 3.59 3.75 3.75 1.62 2.23 1.06 0.46 1.56 0.44 0.19 1.00 0.15 0.05525 0.72 0.06 0.026 5 in. 11.69 52.43 22.70 6.50 12.55 5.43 4.69 5.67 2.46 2.79 1.60 0.69 1.95 0.67 0.29 1.25 0.22 0.09530 0.86 0.08 0.035 0.54 0.03 0.013 14.03 73.48 31.62 7.80 17.59 7.62 5.63 7.95 3.44 3.35 2.25 0.97 2.34 0.94 0.41 1.49 0.31 0.1335 1.00 0.11 0.048 0.63 0.04 0.017 9.10 23.40 10.13 6.57 10.58 4.58 3.91 2.99 1.29 2.73 1.25 0.64 1.74 0.42 0.1340 1.15 0.14 0.061 0.72 0.04 0.017 10.40 29.97 12.98 7.50 13.55 5.87 4.47 3.86 1.66 3.12 1.60 0.89 1.99 0.54 0.2345 1.29 0.17 0.074 0.81 0.05 0.020 6 in. 11.70 37.27 16.14 8.44 16.85 7.30 5.03 4.76 2.07 3.51 1.90 0.86 2.24 0.67 0.2950 1.43 0.21 0.091 0.90 0.07 0.030 0.63 0.03 0.013 13.00 45.30 19.61 9.38 20.48 8.87 5.58 5.79 2.51 3.90 2.42 1.05 2.49 0.81 0.3560 1.72 0.30 0.13 1.08 0.10 0.043 0.75 0.04 0.017 11.26 28.70 12.43 6.70 8.12 3.52 4.68 3.39 1.47 2.98 1.14 0.4970 2.01 0.39 0.17 1.26 0.13 0.056 0.88 0.05 0.022 7.82 10.80 4.68 5.46 4.51 1.35 3.49 1.51 0.6575 2.15 0.45 0.19 1.35 0.14 0.061 0.94 0.06 0.026 8.38 12.27 5.31 5.85 5.12 2.22 3.74 1.74 0.7480 2.29 0.50 0.22 1.44 0.16 0.069 1.00 0.07 0.030 8 in. 8.93 13.83 5.99 6.24 6.77 2.50 3.99 1.94 0.8490 2.58 0.63 0.27 1.62 0.20 0.087 1.13 0.08 0.035 10.05 17.20 7.45 7.02 7.18 3.11 4.48 2.41 1.04100 2.87 0.76 0.33 1.80 0.24 0.10 1.25 0.10 0.043 11.17 20.90 9.05 7.80 8.72 3.78 4.98 2.93 1.27125 3.59 1.16 0.50 2.25 0.37 0.16 1.57 0.16 0.068 0.90 0.045 0.019 9.75 13.21 5.72 6.23 4.43 1.92150 4.30 1.61 0.70 2.70 0.52 0.23 1.88 0.22 0.095 1.07 0.05 0.022 10 in. 11.70 18.48 8.00 7.47 6.20 2.68175 5.02 2.15 0.93 3.15 0.69 0.30 2.20 0.29 0.12 1.25 0.075 0.033 8.72 8.26 3.58200 5.73 2.75 1.19 3.60 0.88 0.38 2.51 0.37 0.16 1.43 0.09 0.039 0.90 0.036 0.015 9.97 10.57 4.58250 7.16 4.16 1.81 4.50 1.34 0.58 3.14 0.56 0.24 1.79 0.14 0.61 1.14 0.045 0.02 12 in. 12.46 16.00 8.93300 8.60 5.33 2.52 5.40 1.87 0.81 3.76 0.78 0.34 2.14 0.20 0.087 1.36 0.07 0.03350 10.03 7.76 3.35 6.30 2.49 1.08 4.39 1.04 0.45 2.50 0.27 0.12 1.59 0.085 0.037 1.12 0.037 0.016400 11.47 9.93 4.30 7.19 3.19 1.38 5.02 1.33 0.68 2.86 0.34 0.15 1.81 0.11 0.048 1.28 0.05 0.022450 8.09 3.97 1.72 5.64 1.65 0.71 3.21 0.42 0.18 2.04 0.14 0.061 1.44 0.06 0.026500 8.99 4.82 2.09 6.27 2.00 0.87 3.57 0.51 0.22 2.27 0.17 0.074 1.60 0.07 0.030750 9.40 4.25 1.84 5.36 1.08 0.47 3.40 0.36 0.16 2.40 0.15 0.0651000 12.54 7.23 3.13 7.14 1.84 0.80 4.54 0.61 0.26 3.20 0.20 0.111250 8.93 2.78 1.20 5.67 0.02 0.40 4.01 0.40 0.171500 10.71 3.89 1.68 6.80 1.29 0.56 4.81 0.55 0.242000 9.07 2.19 0.95 6.41 0.84 0.412500 11.34 3.33 1.44 8.01 1.42 0.623000 9.61 1.99 0.863500 11.21 2.65 1.154000 12.82 3.41 1.48

Friction Loss in Equivalent Feet of Pipe — Schedule 80 Thermoplastics FittingsNominal Pipe Size, In. 3/8 ½ ¾ 1 1¼ 1½ 2 2½ 3 3½ 4 6 8Tee, Side Outlet 3 4 5 6 7 8 12 15 16 20 22 32 3890° Ell 1½ 1½ 2 2¾ 4 4 6 8 8 10 12 18 2245° Ell ¾ ¾ 1 13/8 1¾ 2 2½ 3 4 4½ 5 8 10Insert Coupling — ½ ¾ 1 1¼ 1½ 2 3 3 — 4 6¼ —Male-Female Adapters — 1 1½ 2 2¾ 3½ 4½ — 6½ — 9 14 —

Carrying Capacity and Friction Loss — Schedule 80 Thermoplastics PipeIndependent variables: Gallons per minute and nominal pipe size O.D. (Min. I.D.)Dependent variables: Velocity, friction head and pressure drop per 100 feet of pipe, interior smooth.

Friction Loss — Schedule 80 PipeCarrying capacity, friction loss and flow data for Sched-ule 80 thermoplastic pipe are presented in tabular form in the table below. This table is applicable to pipe made of any of the thermoplastic piping materials as all have equally smooth interior surfaces.

Friction Loss — Schedule 80 FittingsThe table “Friction Loss in Equivalent Feet of Pipe” gives the estimated friction loss in equivalent feet of pipe, through thermoplastic fittings of various sizes and configurations.

21

Head Loss Characteristics of Water Flow Thru Rigid Plastic Pipe

This nomograph provides approximate values for a wide range of plastic pipe sizes. More precise values should be calculated from the Hazen and Williams formula. Experimental test value of C (a constant for inside pipe

The values of this chart are based on the Hazen & Williams formula:

The nomograph is used by lining up values on the scales by means of a ruler or straight edge. Two independent variables must be set to obtain the other values. For example: line (1) indicates that 500 gallons per minute may be obtained with a 6-inch inside diameter pipe at a head loss of about 0.65 pounds per square inch at a velocity of 6.0 feet per second. Line (2) indicates that a pipe with 2.1 inch inside diameter will give a flow of about 60 gallons per minute at a loss in head of 2 pounds per square inch per 100 feet of pipe. Line (3) and dotted line (3) show that in going from a pipe 2.1 inch inside diameter to one of 2 inches inside diameter, the head loss goes from 3 to 4 pounds per square inch in obtaining a flow of 70 gallons per minute. Remember, velocities in excess of 5.0 feet per second are not recommended.

Nomograph courtesy of Plastics Pipe Institute, a division of The Society of The Plastics Industry.

roughness) ranges from 155 to 165 for various types of plastic pipe. Use of a value of 150 will ensure conserva-tive friction loss values.

f = 0.2083 (100)1.852 x g

1.852

C Di4.8655

= 0.0983 g1.852

for C = 150 Di4.8655

P = 4335f

Where:f = Friction Head in ft. of Water per 100 ft. of PipeP = Pressure Loss in psi per 100 ft. of PipeDi = Inside Pipe Diameter, in.g = Flow Rate in U.S. gal./min.C = Constant for Inside Roughness

(C equals 150 for thermoplastics)

22

Installation InstructionsStorage and HandlingGF thermoplastics have excellent resistance to weath-ering and can be stored outside for long periods. However, it is recommended that any plastic pipe stored outside be covered with a light tarpaulin, or kept under cover in a warehouse or shed that is well ventilated to prevent excessive temperature buildup and possible warping. Care should also be exercised to keep the product away from exposure to UV from direct sunlight. The storage area should not be located near steam lines or other heat sources.

To prevent sagging or “draping,” particularly of the longer sections, pipe should be stored on racks that provide close or continuous support. Any sharp edges or burrs on the racks should be removed or covered. To prevent excessive deflection, loose stacks of pipe should not exceed a height of three feet. Bundled pipe can be stacked twice as high.

Fittings and flanges should be kept in their original packaging or in separate bins until they are needed. They should never be mixed with metal piping compo-nents.

Since plastic pipe has lower impact strength and resistance to mechanical abuse than steel, it requires somewhat more care in handling. Pulling a length of pipe off a truck bed and letting the free end plummet to the ground should be avoided. Also to be avoided is dragging the pipe over rough ground, dropping heavy objects on it, or using any kind of chains. The resulting scratches, splits or gouges can reduce the pressure rating.

If damage from careless handling does occur, one of the advantages of plastic pipe is readily apparent. The damaged section can be quickly cut out and the pipe ends rejoined using the cutting and joining techniques described below.

Solvent Welding PVC and CPVC Pipe and FittingsBasic PrinciplesThe solvent cemented connection in thermoplastic pipe and fittings is the last vital link in a plastic pipe instal-

lation. It can mean the success or failure of the system as a whole. Accordingly, it requires the same profes-sional care and attention given to other components of the system.

There are many solvent cementing techniques pub-lished covering step by step procedures on just how to make solvent cemented joints. However, we feel that if the basic principles involved are explained, known and understood, a better understanding would be gained, as to what techniques are necessary to suit particular applications, temperature conditions, and variations in sizes and fits of pipe and fittings.

To consistently make good joints the following should be clearly understood:

1. The joining surfaces must be dissolved and made semi-fluid.

2. Sufficient cement must be applied to fill the gap between pipe and fitting.

3. Assembly of pipe and fittings must be made while the surfaces are still wet and fluid.

4. Joint strength develops as the cement dries. In the tight part of the joint the surfaces will tend to fuse together, in the loose part the cement will bond to both surfaces.

Penetration and dissolving can be achieved by a suit-able primer, or by the use of both primer and cement. A suitable primer will penetrate and dissolve the plastic more quickly than cement alone. The use of a primer provides a safety factor for the installer for he can know, under various temperature conditions, when he has achieved sufficient softening.

23

As the solvent dissipates, the cement layer and the dissolved surfaces will harden with a corresponding increase in joint strength. A good joint will take the required working pressure long before the joint is fully dry and final strength will develop more quickly than in the looser (bonded) part of the joint.

More than sufficient cement to fill the loose part of the joint must be applied. Besides filling the gap, adequate cement layers will penetrate the surface and also remain wet until the joint is assembled. Prove this for yourself. Apply on the top surface of a piece of pipe two separate layers of cement. First apply a heavy layer of cement, then alongside it, a thin brushed out layer. Test the layers every 15 seconds or so by a gentle tap with your finger. You will note that the thin layer becomes tacky and then dries quickly (probably within 15 sec-onds). The heavy layer will remain wet much longer. Check for penetration a few minutes after applying these layers. Scrape them with a knife. The thin layer will have achieved little or no penetration. The heavy one, much more penetration.

If the cement coatings on the pipe and fittings are wet and fluid when assembly takes place, they will tend to flow together and become one cement layer. Also, if the cement is wet the surfaces beneath them will still be soft, and these softened surfaces in the tight part of the joint will tend to fuse together.

24

Making the Joint

1. Cutting: Pipe must be squarely cut to allow for the proper interfacing of the pipe end and the fitting socket bottom. This can be accomplished with a miter box saw or wheel type cutter. For saw cuts on pipe too large for a miter box, a pipe wrap should be used and a line drawn with marker. If using a wheel cutter, it must have a cutting blade specifically designed for plastic pipe.

Note: Power saws should be specifically designed to cut plastic pipe.

2. Deburring: Use a plastic deburring tool or file to remove burrs from the end of small diameter pipe. Be sure to remove all burrs from around the inside as well as the outside of the pipe. A slight chamfer (bevel) of about 10°-15° should be added to the end to permit easier insertion of the pipe into the fitting. Failure to chamfer the edge of the pipe may remove cement from the fitting socket, causing the joint to leak. For pres-sure pipe systems of 2” and above, the pipe must be end-treated with a 15° chamfer cut to a depth of ap-proximately 3/32.” Commercial power bevelers are recommended.

3. Test Dry Fit of the Joint: Tapered fitting sockets are designed so that an interference fit should occur when the pipe is inserted about 1/3 to 2/3 of the way into the socket. Occasionally, when pipe and fitting dimensions are at the tolerance extremes, it will be possible to fully insert dry pipe to the bottom of the fitting socket. When this happens, a sufficient quantity of cement must be applied to the joint to fill the gap between the pipe and fitting. The gap must be filled to obtain a strong, leak-free joint.

A 15° chamfer cut to a depth of approx. 3/32.”

Step 1:

Step 2:

Step 3:

25

Step 4:

Step 5:

4. Inspection, Cleaning, Priming: Visually inspect the inside of the pipe and fitting sockets and remove all dirt, grease or moisture with a clean, dry rag or cloth. If wiping fails to clean the surfaces, a chemical cleaner must be used. Check for possible damage such as splits or cracks and replace if necessary.

Depth-of-Entry Mark: Marking the depth of entry is a way to check if the pipe has reached the bottom of the fitting socket in step #6. Measure the fitting socket depth and mark this distance on the pipe O.D. We recommend that you add a second mark 2” above this mark as the primer and cement may destroy the first mark and this second line can be used to ensure that the pipe is fully inserted into the fitting socket.

Apply primer to the surface of the pipe and fitting socket using an approved applicator, working the primer in the surface of both the fitting socket and pipe O.D. You should continue to vigorously work the primer into these surfaces until you can feel the applicator start to “drag” indicating a softening of the material. It may take several applications of the primer to effectively break down the surface of the material, but this is a critical step in the cementing pro-cess. Move quickly, without hesitation, to the cementing procedure while the surfaces are still wet with primer.

5. Application of Solvent Cement: A critical part of the solvent cementing process is to make sure the cement is well mixed. Periodically cover the container and shake the cement to make sure it stays mixed and uniform. Apply the solvent cement evenly and quickly around the outside of the pipe and at a width a little greater than the depth of the fitting socket while the primer is still wet.

Apply a lighter coat of cement evenly around the inside of the fitting socket. Avoid puddling. Apply a second coat of cementing to the pipe end.

Note: Individual scrape tests may be needed for pipes and fittings from different manufactures or even for pipes of different surface finishes to determine satis-factory penetration and softening of the material.

Caution: Primers and cements are extremely flamma-ble and must not be stored or used near heat or open flame. Read all warnings on primer and cement cans.

26

Note: It may be necessary for two workers to perform this operation for larger sizes of pipe.

For sizes 6” and above, and possibly 4” in hot weather, we recommend the consideration of two-man crews to effec-tively prime both pipe and fitting surfaces and apply the cement while the material is still wet with primer.

Note: When cementing bell-end pipe, be careful not to apply an excessive amount of cement to the bell socket. This will prevent solvent damage to the pipe. For buried pipe applications, do not throw empty primer or cement cans into the trench along side the pipe. Cans of cement and primer should be closed at all times when not in use to prevent evaporation of chemicals and hardening of cement.

6. Joint Assembly: Working quickly, squarely insert the pipe into the fitting socket, giving the pipe or fitting a ¼ turn during insertion to evenly distribute the cement. Do not continue to rotate the pipe after it has hit the bottom of the fitting socket. A good joint will have sufficient cement to form a uniform bead all the way around the outside of the fitting hub. The fitting will have a tendency to slide back on the pipe while the cement is setting, so hold the joint tightly together for about 30 seconds. Please use the cement manufacturer’s written recommendations regarding joint set time, for initial movement of a joint, and cure time be-fore a pressure test. For pipe sizes 4” and above, greater axial forces are necessary for the assembly of interference fit joints. Mechanical forcing equipment may be needed to join the pipe and hold the joint until the cement “sets.” The joint may have to be held together for up to 3 minutes. Consult the factory for specifics.

Note: Always wait at least 24 hours before pressure testing a piping system to allow cemented joints to cure properly. For colder temperatures, it may be necessary to wait a longer period of time. Please reference the solvent cement manufacturer’s curing time.

Note: When using mechanical joining equipment, it will not be possible to apply the ¼ turn as the pipe is inserted into the fitting.

7. Clean-up and Joint Movement: Remove all excess ce-ment from around the pipe and fitting with a dry, cotton rag or cloth. This must be done while the cement is still soft.

The joint should not be disturbed immediately after the cementing procedure and sufficient time should be allowed for proper curing of the joint. Exact drying time is difficult to predict because it depends on variables such as tem-perature, humidity and cement integrity. For more specific information, contact your solvent cement manufacturer.

Step 6:

Step 7:

Step 5: (cont.)

27

Joining Plastic Pipe in Hot Weather

There are many occasions when solvent cementing plastic pipe in 95°F temperatures and over cannot be avoided. At surface temperatures exceeding 110°F, we recommend that the solvent cement manufacturer be contacted. If special precautions are taken, problems can be avoided.

Solvent cements for plastic pipe contain high-strength solvents which evaporate faster at elevated tempera-tures. This is especially true when there is a hot wind blowing. If the pipe is stored in direct sunlight, surface temperatures may be 20°F to 30°F above air tempera-ture. Solvents attack these hot surfaces faster and deeper, especially inside a joint. Thus it is very impor-tant to avoid puddling inside socket and to wipe off excess cement outside.

By following our standard instructions and using a little extra care, as outlined below, successful solvent cemented joints can be made in even the most extreme hot weather conditions.

Tips to Follow When Solvent Cementing in High Temperatures

1. Store solvent cements and primers in a cool or shaded area prior to use.

2. If possible, store fitting and the pipe, or at least the ends to be solvent welded, in shady area before cementing.

3. Cool surfaces to be joined by wiping with a damp rag. Be sure that surfaces dry prior to applying solvent cement.

4. Try to do the solvent cementing in cooler morning hours.

5. Make sure that both surfaces to be joined are still wet with cement when putting them together. With large size pipe, more people on the crew may be neces-sary.

6. Use a heavier, high viscosity cements since they will provide a little more working time.

As you know, during hot weather there can be a greater expansion-contraction factor.

Joining Plastic Pipe in Cold Weather

Working in freezing temperatures is never easy. But sometimes the job is necessary. If that unavoidable job includes cementing plastic pipe, you can do it success-fully with regular cements.

Good Joints Can Be Made at Sub-Zero Temperatures

By following standard instructions and using a little extra care and patience, successful solvent cemented joints can be made at temperatures even as low as -15°F. In cold weather, solvents penetrate and soften the surfaces more slowly than in warm weather. Also the plastic is more resistant to solvent attack. There-fore, it becomes more important to pre-soften surfaces with a primer. And, because of slower evaporation, a longer cure time is necessary. Cure schedules already allow a wide margin for safety. For colder weather, simply allow more time.

Tips to Follow in Solvent Cementing During Cold Weather

1. Prefabricate as much of the system as possible in a heated working area.

2. Store cements and primers in a warmer area when not in use and make sure they remain fluid.

3. Take special care to remove moisture including ice and snow.

4. Use a primer to soften the joining surfaces before applying cement.

5. Allow a longer cure period before the system is used.6. Read and follow all of our directions carefully before

installation.

Regular cements are formulated to have well balanced drying characteristics and to have good stability in sub-freezing temperatures. Some manufacturers offer special cements for cold weather because their regular cements do not have that same stability.

For all practical purposes, good solvent cemented joints can be made in very cold conditions with existing prod-ucts, provided proper care and a little common sense are used.

Guideline on Cement Usage

Pipe Size ½” ¾” 1” 1¼” 1½” 2” 2½” 3” 4” 6” 8” 10” 12”

No. of Joints 300 200 125 105 90 60 50 40 30 10 5 2-3 1-2

Note: This information is provided as a general guide-line. Recommendation is for the number of joints per quart. A Tee will have 3 joints, an Ell will have 2 joints. Our recommendation for primer is to use 150% of the cement number.

28

Threading

While threaded thermoplastic systems are not recom-mended for high-pressure systems, piping layouts where leaks would be dangerous, or for larger pipe sizes (more than two inches), they have two definite advantages. They quickly can be dismantled for tempo-rary or take-down applications; and they can be used to join plastic to nonplastic materials.

Following are recommendations for making threaded joints with thermoplastic pipe and fittings.

1. Thread only pipes that have wall thicknesses equal to or greater than those of Schedule 80 pipe.

2. For pressure-rated pipes of PVC and CPVC reduce the pressure rating of threaded pipe to one-half that of unthreaded pipe.

3. To cut the threads, use only pipe dies designed for plastic pipes. Keep the dies clean and sharp. Do not cut other materials with them.

4. Vises for holding the pipe during thread cutting and pipe wrenches should be designed and used in such a manner that the pipe is not damaged. Strap wrenches are recommended. Wooden plugs can be inserted into the end of the pipe, if needed to prevent distortion of the pipe walls and cutting of off-center threads.

5. The following general procedure for cutting threads may be used:

A. Use a die stock with a proper guide so the die will start and go on square to the pipe axis. Any burrs or sharp edges on the guide that can scratch the pipe must be removed.

B. Do not use cutting oil. However, a drop of oil may be rubbed onto the chasers occasionally. This prevents tearing and helps to promote clean, smooth threads.

C. If lubrication is necessary, it is best to use a water based lubricant.

6. Before assembly, the threads should be lubricated and sealed with a non-hardening pipe dope or wrapped with Teflon® tape.

7. The proper threading of plastic parts requires some cautions and concerns to maintain the integrity of the threads. Since plastic threads can be easily damaged or cross threaded, it is important that these threads

be properly lubricated using a pipe dope, which is compatible with the materials being threaded, or TFE tape.

TFE taped must be installed in a clockwise direction, starting at the bottom of the thread and overlapping each pass. Do not employ more than 3 wraps.

The starting of the thread is critical, to avoid thread damage which could result in a leak. Product must never be installed more than ½ - 1 turn past hand tight and only strap wrenches should be used to tighten plastic connections.

8. In general, applications for threaded plastic pipe fit-tings fall into two categories:

A. Fittings for use in an all-plastic system where both the male and female parts are plastic.

B. Fittings for use as transition fittings from plastic to metal.

Theoretically, it is possible to use any combination of threaded parts such as:

1. Metal male to plastic female.

2. Plastic male to plastic female.

3. Metal female to plastic male.

Practical experience, however, suggests that the METAL MALE TO PLASTIC FEMALE combination is more susceptible to premature failure than the other two applications.

The reason for this is due to the incompressibility of metal. Standard instructions call for the male part to be run in hand tight and then tightened ½ turn more. It has been our observation, however, that it is very common to find male metal parts screwed in for a total of 7 to 8 threads. This results in excessively high stress levels in the plastic female part.

The tensile strength of the Type I PVC is 7200 psi. However, all fittings have knit lines (where the melted material joins together after flowing around the core which forms the waterway) which are the weakest por-tions of the fitting. The tensile strength at the knit lines is therefore lower than the minimum of 7200 psi. A metal nipple screwed in 7½ turns will generate a stress

Teflon® is a registered trademark of E.I. DuPont de Nemours & Co.

29

of approximately 6600 psi. This means that if the fitting doesn’t crack open immediately, there will probably be a small crack initiated on the inside which will ultimately cause failure. It is for this reason that George Fischer Piping Systems recommends that its threaded plastic pipe fittings be used only in the following two combina-tions:

1. PLASTIC MALE TO PLASTIC FEMALE2. PLASTIC MALE TO METAL FEMALE

If it is absolutely necessary to use a plastic female thread for transition to metal nipple, then it is IMPERA-TIVE that the nipple not be turned more than ½ turn past HANDTIGHT (“fingertight” for strong hands). To insure a leakproof joint, a good sealant is recommended (Teflon® tape or Teflon® pipe dope).

Note: Angle between sides of thread is 60 degrees. Taper of thread, on diameter, is ¾ inch per foot.

The basic thread is 0.8 x pitch of thread and the crest and root are truncated an amount equal to 0.033 x pitch, excepting 8 threads per inch which have a basic depth of 0.788 x pitch and are truncated 0.045 x pitch at the crest and 0.033 x pitch at the root.

American Standard Taper Pipe Thread DimensionsPipe Thread

Nominal Size (in.)

Outside Diameter (in.)

Number of Threads Per Inch

Normal Engagement by hand (in.)

Length of Effective Thread (in.)

Total Length End of Pipe to Vanish Point (in.)

Pitch Diameter at End of Internal Thread (in.)

Depth of Thread (Max.) (in.)

D C A B E1/8 .405 27 .180 .2639 .3924 .39476 .02963¼ .540 18 .200 .4018 .5946 .48989 .044443/8 .675 18 .240 .4078 .6006 .62701 .04444½ .840 14 .320 .5337 .7815 .77843 .05714¾ 1.050 14 .339 .5457 .7935 .98887 .057141 1.315 11½ .400 .6828 .9845 1.23863 .069571¼ 1.660 11½ .420 .7068 1.0085 1.58338 .069571½ 1.900 11½ .420 .7235 1.0252 1.82234 .069572 2.375 11½ .436 .7565 1.0582 2.29627 .069572½ 2.875 8 .682 1.1375 1.5712 2.76216 .100003 3.500 8 .766 1.2000 1.6337 3.38850 .100003½ 4.000 8 .821 1.2500 1.6837 3.88881 .100004 4.500 8 .844 1.3000 1.7337 4.38713 .100005 5.563 8 .937 1.4063 1.8400 5.44929 .100006 6.625 8 .958 1.5125 1.9472 6.50597 .100008 8.625 8 1.063 1.7125 2.1462 8.50003 .1000010 10.750 8 1.210 1.9250 2.3587 10.62094 .1000012 12.750 8 1.360 2.1250 2.5587 12.61781 .10000

30

FlangingThe use of flanges in a PVC/CPVC piping system may have an advantage if there is a need to dismantle the pipe, when the sys-tem is temporary and mobility is required or when transitioning to dissimilar materials. Flanging should also be considered when it is environmentally impossible to make solvent cemented joints on location.

Selection of Materials1. Gasket: full faced elastomeric material (Durometer “A” Scale of

55 to 80) usually 1/8” thick. Gasket material must be resistant to the media in the pipe.

2: Fasteners: All nuts, bolts and flat washers must be resistant to the chemical environment. All listed torque values are using well lubricated bolt threads. Flat washers are required for both the nut and the bolt head to minimize point loading on the flange. We recognize that some facilities do not allow lubrication, but the variables to determine torque values in such situations are beyond the scope of this document and require specific engineer-ing considerations.

3. Torque Wrench: A necessity for tightening bolts to prevent exces-sive or uneven torque.

Flange Assembly1. Join the flange to the pipe. Solvent cemented joints must be

allowed sufficient cure time per the manufacturer’s written rec-ommendations prior to any movement or assembly

2. Align the flanges and gasket by inserting all the bolts through the matching bolt holes. Proper mating of flanges and gaskets is very important for a positive seal. Misalignment of flanges (Cold Springing), pulling the flanges together, as well as uneven torque can result in premature, possibly catastrophic, failure.

3. Use a torque wrench: The proper torque, as well as the gradual tightening of the bolts, is necessary to secure an effective seal and minimize those condi-tions which could lead to premature failure.

Note:1. Do not over-torque flange bolts.2. Use the proper bolt tightening sequence.3. Make sure the system is in proper alignment.4. Flanges should not be used to draw piping as-

semblies together.5. Flat washers must be used under every nut and

bolt head.

Flange Bolt Tightening Pattern(tighten bolts evenly: follow numericalsequence)

Recommended TorquePipe Size (IPS)

No. Bolt Holes

Bolt Diameter

Approx. Bolt Length*

Recommended Torque ft/lbs

½ 4 ½ 2½ 10-15

¾ 4 ½ 2½ 10-15

1 4 ½ 2½ 10-15

1¼ 4 ½ 3 10-15

1½ 4 ½ 3 10-15

2 4 5/8 3 20-30

2½ 4 5/8 3½ 20-30

3 4 5/8 3¾ 20-30

4 8 5/8 4 20-30

6 8 ¾ 4¾ 33-50

8 8 7/8 5¼ 33-50

10 12 7/8 6 53-75

12 12 7/8 6½ 53-75

*Bolt lengths were calculated using two flanges. Additional accessories or different mating surfaces will alter these numbers.

Note: Flange bolt hole pattern meets ANSI B16.5.

31

Above-Ground Installation

Support Spacing

When thermoplastic piping systems are installed above-ground, they must be properly supported to avoid unnecessary stresses and possible sagging.

Horizontal runs require the use of hangers as described on the next page, spaced approximately as indicated in the table below. Note that additional support is re-quired as temperatures increase. Continuous support can be accomplished by the use of smooth structural angle or channel.

Where the pipe is exposed to impact damage, protective shields should be installed.

Tables are based on the maximum deflection of a uni-formly loaded, continuously supported beam calculated from:

y = .00541 wL4

EIWhere: y = Deflection or sag (in.) w = Weight per unit length (lb./in.) L = Support spacing (in.) E = Modulus of elasticity at given temperature

(lb./in.2) I = Moment of inertia (in.4)

If 0.100 in. is chosen arbitrarily as the permissible sag (y) between supports, then:

L4 - 18.48 EL wWhere: w = Weight of pipe + weight of liquid (lb./in.)For a pipe I = (Do4-Di4) 64Where: Do = Outside diameter of the pipe (in.) Di = Inside diameter of the pipe (in.)

Then:L = (.907 E (Do4-Di4))

¼

W

= .976 ( E Do4-Di4)¼

W

Recommended Support Spacing* (In Feet)Nom. Pipe Size (In.)

PVC Pipe CPVC Pipe

Schedule 40 Schedule 80 Schedule 80

Temp. °F Temp. °F Temp. °F

60 80 100 120 140 60 80 100 120 140 60 80 100 120 140 180

½ 4½ 4½ 4 2½ 2½ 5 4½ 4½ 3 2½ 5½ 5½ 5 4½ 4½ 2½

¾ 5 4½ 4 2½ 2½ 5½ 5 4½ 3 2½ 5½ 5½ 5½ 5 4½ 2½

1 5½ 5 4½ 3 2½ 6 5½ 5 3½ 3 6 6 6 5½ 5 3

1¼ 5½ 5½ 5 3 3 6 6 5½ 3½ 3 6½ 6½ 6 6 5½ 3

1½ 6 5½ 5 3½ 3 6½ 6 5½ 3½ 3½ 7 7 6½ 6 5½ 3½

2 6 5½ 5 3½ 7 7 6½ 6 4 3½ 7 7 7 6½ 6 3½

2½ 7 6½ 6 4 3½ 7½ 7½ 6½ 4½ 4 8 7½ 7½ 7½ 6½ 4

3 7 7 6 4 3½ 8 7½ 7 4½ 4 8 8 8 7½ 7 4

4 7½ 7 6½ 4½ 4 9 8½ 7½ 5 4½ 9 9 9 8½ 7½ 4½

6 8½ 8 7½ 5 4½ 10 9½ 9 6 5 10 10½ 9½ 9 8 5

8 9 8½ 8 5 4½ 11 10½ 9½ 6½ 5½ 11 11 10½ 10 9 5½

10 10 9 8½ 5½ 5 12 11 10 7 6 11½ 11½ 11 10½ 9½ 6

12 11½ 10½ 9½ 6½ 5½ 12 11 10 7 6 12½ 12½ 12½ 11 10½ 6½

14 12 11 10 7 6 13½ 13 11 8 7

16 12½ 11½ 10½ 7½ 6½ 14 13½ 11½ 8½ 7½

Note: This data is based on information supplied by the raw material manufacturers. It should be used as a general rec-

ommendation only and not as a guarantee of performance or longevity.

*Chart based on spacing for continuous spans and for uninsulated lines conveying fluids of specific gravity up to 1.00.

32

Hangers

There are many hangers and supports suitable for use in plastic piping systems, although some may require modification. It is important in a plastic piping system to provide a wide load-bearing surface and that any restraints recognize that vinyl piping systems are somewhat notch sensitive. Also, if the thermal move-ment of a plastic piping system might cause the pipe-line to abrade on a rough surface, such as concrete, some means of isolating the pipe should be considered. Wear pads of plastic can be fashioned from the pipe or wooden isolators can be used.

It is also important to recognize the thermal movement in any plastic piping system and the hangers and sup-port structures should allow for, or direct, the expan-sion that may be in a particular system. Pipe hangers must be carefully aligned and must have no rough or sharp edges that could contact and potentially damage the pipe. The hanger or support system should recog-nize the thermal expansion in a plastic pipe system and pipe should be allowed to move.

Vertical lines must also be supported at intervals so that the fittings at the lower end of a riser or column are not overloaded. The supports should not exert a com-pressive strain on the pipe, such as riser–type clamps that squeeze the pipe. A double bolt type, in conjunc-tion with using a fitting shoulder, may afford the best method for supporting vertical systems.

Sunlight and Plastics

Plastic pipe and fittings have been used extensively outdoors and are resistant to weathering, but may have some surface degradation from intense and prolonged exposure to the ultraviolet (UV) rays in sunlight. This degradation is a surface effect, reducing the impact rating but has no affect on the temperature capability as well as the chemical resistance or pressure rating of the pipe. This reduced impact rating can be eliminated by removal of the affected surface area and covering with a good bonding exterior latex paint.

The latex paint must be applied thick enough, probably several coats, to create an opaque covering. If the pipe and fittings are prepared properly for painting (clean-ing and very light sanding), a good grade of exterior latex should last for many years. White or light colored pigment is suggested, which offers a more reflective surface.

Single Pipe Roll

Recommended Hangers for Plastic Piping Systems

Band Hanger with Protective Sleeve

Clevis

Adjustable Solid Ring Swivel Type

Roller Hanger

Pipe Roll and Plate

Riser Clamp

Double-Bolt Clamp

33

Typical Method of Anchorage

A Typical Method of Anchorage of a Change in Direction

Typical Support Arrangements

Anchors and Guides

Anchors in a piping system direct movement of pipe within a defined reference frame. At the anchoring point, there is no axial or transverse movement. Guides are used to allow axial movement of pipe but prevent transverse movement. Anchoring and guides should be engineered to provide the required function without point loading the plastic pipe.

Guides and anchors are used whenever expansion joints are used and are also on long runs and directional changes inpiping.

Continuous Support Arrangements

34

Below-Ground Installation

Trenching and Bedding

1. Depth: When installing underground piping systems, the depth of the trench is determined by the intended service and by local conditions (as well as by local, state and national codes that may require a greater trench depth and cover than are technically necessary).

Underground pipes are subjected to external loads caused by the weight of the backfill material and by loads applied at the surface of the fill. These can range from static to dynamic loads.

Static loads comprise the weight of the soil above the top of the pipe plus any additional material that might by stacked above ground. An important point is that the load on a flexible pipe will be less than on a rigid pipe buried in the same manner. This is because the flexible conduit transfers part of the load to the surrounding soil and not the reverse. Soil loads are minimal with narrow trenches until a pipe depth of 10 feet is attained.

Dynamic loads are loads due to moving vehicles such as trucks, trains and other heavy equipment. For shallow burial conditions, live loads should be considered and added to static loads, but at depths greater than 10 feet, live loads have very little effect.

For static and dynamic soil loading tables, refer to spe-cific materials sections, PVC and CPVC.

Pipe intended for potable water service should be buried at least 12 inches below the maximum expected frost penetration.

2. Bedding: The bottom of the trench should provide a firm, continuous bearing surface along the entire length of the pipe run. It should be relatively smooth and free of rocks. Where hardpan, ledge rock or boulders are present, it is recommended that the trench bottom be cushioned with at least four (4) inches of sand or com-pacted fine-grained soils.

3. Snaking: To compensate for thermal contraction, the snaking technique of offsetting the pipe with relation to the trench centerline is recommended.

Example: Snaking is particularly important when lay-ing small diameter pipe in hot weather. For example, a 100-foot length of PVC Type I pipe will expand or con-tract about ¾” for each 20°F temperature change. On a hot summer day, the direct rays of the sun on the pipe can drive the surface temperature up to 150°F. At night, the air temperature may drop to 70°F. In this hypotheti-cal case, the pipe would undergo a temperature change of 80°F — and every 100 feet of pipe would contract 3”. This degree of contraction would put such a strain on newly cemented pipe joints that a poorly made joint might pull apart.

Installation: A practical and economical method is to cement the line together at the side of the trench during the normal working day. When the newly cemented joints have dried, the pipe is snaked from one side of the trench to the other in gentle, alternative curves. This added length will compensate for any contraction after the trench is backfilled (see “Snaking of Pipe Within Trench” illustration below).

The “Snaking Length” table below gives the required loop length, in feet, and offset in inches, for various temperature variations.

Snaking Length vs. Offset (in.) to Compensate for Thermal ContractionSnaking Length, (ft.)

Maximum Temperature Variation (°F) Between Time of Cementing and Final Backfilling

10° 20° 30° 40° 50° 60° 70° 80° 90° 100°

Loop Offset, (in.)

20 2.5 3.5 4.5 5.20 5.75 6.25 6.75 7.25 7.75 8.0050 6.5 9.0 11.0 12.75 14.25 15.50 17.00 18.00 19.25 20.25

100 13.0 18.0 22.0 26.00 29.00 31.50 35.00 37.00 40.00 42.00

Snaking of Pipe Within Trench

Snaking of thermoplastic pipe within trench to compensate for contraction.

35

Anchors and Other Connections

Plastic pipe is not designed to provide structural strength beyond sustaining internal pressures up to its designed hydrostatic pressure rating and normal soil loads. Anchors, valves and other connections must be independently supported to prevent added shearing and bending stresses on the pipe.

Risers: The above piping design rule applies also where pipe is brought out of the ground. Above-ground valves or other connections must be supported inde-pendently. If pipe is exposed to external damage, it should be protected with a separate, rigidly supported metal pipe sleeve at the danger areas. Thermoplastic pipe should not be brought above ground where it is exposed to high temperatures. Elevated temperatures can lower the pipe’s pressure rating below design lev-els.

Backfilling

Before making the final connections and backfilling, the pipeline should be cooled to near the temperature of the soil. During hot weather, for example, backfilling should be done early in the morning, when the solvent-cemented joints are completely dried and the line is fully contracted.

Assuming that the pipe is uniformly and continuously supported over its entire length on firm, stable mate-rial, it should first be covered with 6 to 8 inches of soil that is free of debris and rocks larger than one-half inch in diameter. This initial layer should be compacted by hand or, preferably, by mechanical tamper so that it acts as a protective cushion against the final backfill. Any large, sharp rocks that could penetrate the tam-pered layer around the pipe should be removed from the final backfill.

Heavy Traffic: When plastic pipe is installed beneath streets, railroads or other surfaces that are subjected to heavy traffic and resulting shock and vibration, it should be run within a protective metal or concrete cas-ing.

Locating Buried Pipe: The location of plastic pipelines should be accurately recorded at the time of installa-tion. Since pipe is a non-conductor, it does not respond to the electronic devices normally used to locate metal pipelines. However, a copper or galvanized wire can be spiraled around, taped to or laid alongside or just above the pipe during installation to permit the use of a locat-ing device.

Note: For additional information, see ASTM D-2774, “Underground Installation of Thermoplastic Piping.”

36

Soil Load and Pipe Resistance for Flexible Thermoplastic Pipe —PVC Schedule 80 Pipe

Nom. Size

Wc’ = Load Resistance of Pipe (lb./ft.)

H=Height of fill above pipe

Wc = Soil Loads at Various Trench Widths at Top of Pipe (lb./ft.)

Schedule 80 Pipe

E’ = 200 E’ = 700 (ft.) 2 ft 3 ft. 4 ft. 5 ft.

1½ 1375 1561

10 106 125 136 152

20 138 182 212 233

30 144 207 254 314

40 — 214 269 318

2 1161 1400

10 132 156 170 190

20 172 227 265 291

30 180 259 317 392

40 — 267 337 398

2½ 1593 1879

10 160 191 210 230

20 204 273 321 352

30 216 306 377 474

40 — 323 408 482

3 1416 1772

10 196 231 252 280

20 256 336 392 429

30 266 266 384 469

40 — 394 497 586

3½ 1318 1731

10 223 266 293 320

20 284 380 446 490

30 300 426 524 660

40 — 450 568 670

4 1266 1735

10 252 297 324 360

20 328 432 540 551

30 342 493 603 743

40 — 506 639 754

5 1206 1796

10 310 370 407 445

20 395 529 621 681

30 417 592 730 918

40 — 625 790 932

6 1323 2028

10 371 437 477 530

20 484 636 742 812

30 503 725 888 1093

40 — 745 941 1110

8 1319 2250

10 483 569 621 690

20 630 828 966 1057

30 656 945 1156 1423

40 — 970 1225 1415

10 1481 2649

10 602 710 774 860

20 785 1032 1204 1317

30 817 1177 1405 1774

40 — 1209 1527 1801

12 1676 3067

10 714 942 919 1020

20 931 1225 1429 1562

30 969 1397 1709 2104

40 — 1434 1811 2136

Note 1: Figures are calculated from minimum soil resistance values (E’ = 200 psi for uncompacted sandy clay foam) and compacted soil (E’ = 700 for side-fill soil that is compacted to 90% or more of Proc-tor Density for distance of two pipe diameters on each side of the pipe). If Wc’ is less than Wc at a given trench depth and width, then soil compaction will be necessary.

Note 2: These are soil loads only and do not include live loads.

WH

WH

WH

WH

Trench Widths for PVC

Note: W = Trench Width at Top of Pipe.

37

StandardsStandards allow an engineer to develop a specification which will provide accepted material and product per-formance. Having strong industry standards provides the market with the necessary criteria to determine the suitability of a specific material and/or product for a spe-cific application. Within the plastics industry the primary source of these standards is ASTM which are usually the basis of most specifications.

Manufacturers may also subscribe to other standards, such as IAPMO, NSF, ANSI, ASME and UL. For the purposes of this manual we will restrict our listing of standards to those that are relevant to Schedule 80 PVC and CPVC.

ASTM (American Society for Testing and Materials)D-1784: ”Standard Specification for Rigid Poly(vinyl Chloride) (PVC) and Chlorinated Poly(Vinyl Chloride) (CPVC) Compounds”

This specification covers the compound materials physi-cal requirements for PVC and CPVC pipe, valves and fit-tings based on several physical and chemical properties.

D-1785: “Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe, Schedules 40, 80 and 120”

This specification covers poly(vinyl chloride) (PVC) pipe made in Schedule 40, 80 and 120 sizes and pressure-rated for water. Included are criteria for classifying PVC plastic pipe materials and PVC plastic pipe, a system of nomenclature for PVC plastic pipe and requirements and test methods for materials, workmanship, dimensions, sustained pressure, burst pressure, flattening, and extrusion quality.

D-2466: “Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 40”

This specification covers poly(vinyl chloride) (PVC) Schedule 40 pipe fittings. Included are requirements for material, workmanship, dimensions, and bust pressure.

D-2467: “Standard Specification for Poly(Vinyl Chloride) (PVC) Plastic Pipe Fittings, Schedule 80”

This specification covers poly(vinyl chloride) (PVC) Schedule 80 pipe fittings. Included are requirements for

materials, workmanship, dimensions, and burst pres-sure.

D-2672: “Standard Specification for Joints for IPS PVC Pipe using Solvent Cement”

This specification covers the socket produced for sol-vent cements joints on both pressure and non-pressure IPS pipe. It also covers the testing of the joints on both pressure and non-pressure pipe, and includes require-ments for socket dimensions, burst pressure, and joint tightness tests of the solvent cemented joints. The tests described are not intended for routine quality control, but rather to evaluate the performance characteristics of the joint.

D-2855: “Standard Practice for Making Solvent- Cemented Joints with Poly(Vinyl Chloride) (PVC) Pipe and Fittings”

This recommended practice describes, in detail, proce-dures for making solvent cemented joints. Preparation of the surfaces, applying the cement, making the assem-bly, handling after assembly, testing and a schedule of drying times related to temperature and pipe sizes are covered.

F-1498: “Standard Specification for Taper Pipe Threads 60° for Thermoplastic Pipe and Fittings”

This specification established requirements for dimen-sions and gauging of taper pipe threads used on threaded plastic pipe and fittings.

F-402: “Standard Practice for Safe Handling of Solvent Cements, Primers, and Cleaners Used for Joining Ther-moplastic Pipe and Fittings”

This recommended practice covers procedures for the safe handling of solvent cements containing solvents which may be flammable, toxic or irritants. It recom-mends precautions and safeguards against the hazards of fire.

F-437: “Standard Specification for Threaded Chlori-nated Poly(Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Schedule 80”

This specification covers chlorinated poly(vinyl chloride) (CPVC) threaded Schedule 80 pipe fittings. Included are requirements for materials, workmanship, dimensions,

38

and burst pressure.

F-439: “Standard Specification for Chlorinated Poly(Vinyl Chloride) (CPVC) Plastic Pipe Fittings, Sched-ule 80”

This specification covers chlorinated poly(vinyl chloride) (CPVC) Schedule 80 pipe fittings. Included are require-ments for materials, workmanship, dimensions, and burst pressure.

F-441: “Standard Specification for Chlorinated Poly(Vinyl Chloride) (CPVC) Plastic Pipe, Schedules 40 and 80”

This specification covers chlorinated poly(vinyl chloride) (CPVC) pipe made in Schedule 40 and 80 sizes and pres-sure-rated for water. Included are criteria for classifying CPVC plastic pipe materials and CPVC plastic pipe, a system of nomenclature for CPVC materials, workman-ship, dimensions, sustained pressure, burst pressure, flattening and extrusion quality. Methods of marking are also given.

ASME/ANSI (American Society of Mechanical Engineers / American National Standards Institute)These standards were developed for metal pipe systems and some or all of the components have been adopted by the plastic piping industry. It its extremely important for the engineer or specifying influence to understand the scope of these standards and the extent to which plastic piping will conform.

B16.6: Flanges and Flanged Piping

In plastic piping systems, this standard is used to estab-lish the flange O.D., bolt hole pattern and bolt hole size.

B1.20.1: National Pipe Thread Taper - Pipe Thread Dimensions

This is a dimensional specification covering standard tapered pipe threads, identified by GF Piping Systems as FPT (Female Pipe Thread ) and MPT (Male Pipe Thread).

NSF/ANSI (National Sanitation Foun-dation / American National Standards Institute)This company acts as the third-party certification agency for the plastics industry, as well as providing a certifica-tion regarding the acceptability of product for certain applications, such as potable water or chemical waste.

Standard 14: Plastic Piping Systems Components and Related Materials

This standard applies to inspection for compliance with all relevant industry standards. This primarily relates to ASTM but NSF will certify compliance with any standards the company publicly claims to meet.

Standard 61: Drinking Water Systems Components – Health Effects

This standard relates to the suitability of product in potable water systems.

39

Sample SpecificationPVC Schedule 40 Pipe and Fittings

Scope: This sample specification covers the manufacturer’s requirements for PVC Schedule 40 pipe and fittings manufactured of Rigid Poly (Vinyl chloride) (PVC). All pipe and fittings shall be as manufactured by Georg Fischer Piping Systems, Little Rock, Arkansas.

Materials: All materials shall be PVC type I, Grade I, meeting, or exceeding, the requirements of ASTM D-1784, cell classification 12454-B. All compound components shall be listed with NSF and meet the requirements of ANSI/NSF Standard 61 as suitable for Potable Water.

Pipe: All PVC Schedule 40 pipe shall meet, or exceed, the requirements of ASTM D-1785. Any pipe bells shall meet the requirements of ASTM D-2672. All piping shall be listed with NSF under Standards 14/61 and shall carry the NSF seal for suitability with Potable Water.

Fittings: All PVC Schedule 40 fittings shall meet, or exceed the requirements of ASTM D-2466 and shall be listed with NSF under standards 14/61. Product shall carry the NSF seal for suitability with Potable Water.

Installation: Installation and testing shall be in accordance with accepted engineering and installation practices as noted in the Georg Fischer Piping Systems Technical Manual as well as the solvent cement manufacturer’s written in-structions. To ensure compatibility all pipe, valves and fittings shall be manufactured and supplied by Georg Fischer Piping Systems.

******** CAUTION ******** Do not test with Air or Air over Water.

40

Sample SpecificationCPVC Schedule 80 Pipe and Fittings

Scope: This sample specification covers the manufacturer’s requirements for CPVC Schedule 80 pipe and fittings manufactured of Rigid Chlorinated Poly (Vinyl Chloride) (CPVC). All pipe, valves and fittings shall be as manufactured and supplied by Georg Fischer Piping Systems, Little Rock, Arkansas.

Materials: All materials shall be CPVC Type IV, Grade I, cell classification 23447-B, and shall meet, or exceed, the requirements of ASTM D-1784. All compound components shall be listed with NSF under Standard 61 and be certi-fied as suitable for potable water systems.

Pipe: All CPVC Schedule 80 pipe shall meet, or exceed, the requirements of ASTM F-441. Any pipe bells shall meet the requirements of ASTM D-2672. All pipe shall be listed with NSF under Standards 14/61 and shall carry the NSF seal for Potable Water. Any threaded PVC 80 pipe shall meet the requirements of ASME/ANSI B1.20.1 and shall be ac-complished with pipe dies specifically designed for use with plastic pipe.

Fittings: Socket: All CPVC Schedule 80 fittings shall meet, or exceed, the dimensional and tolerance requirements of

ASTM F-439Threads: All PVC Schedule 80 threaded fittings shall meet, or exceed, the dimensional and tolerance requirements of

ASTM F-437All fittings shall meet, or exceed, the requirements of ASTM F 439 and shall be listed with NSF under standards 14/61 and shall carry the NSF seal for Potable Water.

Valves: All valves shall be of compatible materials utilizing EPDM or FPM O-rings and seals with TFE seats as manu-factured and supplied by Georg Fischer Piping Systems.

Installation: Installation and testing shall be in accordance with accepted engineering and installation practices as noted in the Georg Fischer Piping Systems Technical Manual as well as the solvent cement manufacturer’s written in-structions. To ensure compatibility all pipe, valves and fittings shall be manufactured and supplied by Georg Fischer Piping Systems.

******** CAUTION ******** Do not test with Air or Air over Water.

41

Sample SpecificationPVC Schedule 80 Pipe and Fittings

Scope: This sample specification covers the manufacturer’s requirements for PVC Schedule 80 pipe and fittings manufactured of Rigid Poly (Vinyl Chloride) (PVC). All pipe, valves and fittings shall be as manufactured and supplied by Georg Fischer Piping Systems, Little Rock, Arkansas.

Materials: All materials shall be PVC Type I, Grade I, with a cell classification of 12424-B, and shall meet, or exceed, the requirements of ASTM D-1784. All compound components shall be listed with NSF and meet the requirements of NSF Standard 61 as suitable for potable water.

Pipe: All PVC Schedule 80 pipe shall meet, or exceed, the requirements of ASTM D-1785. Any pipe bells shall meet the requirements of ASTM D-2672. All pipe shall be listed with NSF under Standards 14/61 and shall carry the NSF seal for Potable Water. Any threaded PVC 80 pipe shall meet the requirements of ANSI B1.20.1 and shall be accom-plished with pipe dies specifically designed for use with plastic pipe.

Fittings: Socket: All PVC Schedule 80 fittings shall meet, or exceed, the dimensional and tolerance requirements of

ASTM D-2467Threads: All PVC Schedule 80 threaded fittings shall meet, or exceed, the dimensional and tolerance requirements of

ASTM D-2464All fittings shall be listed with NSF under standards 14/61 and shall carry the NSF seal for Potable Water.

Valves: All valves shall be of compatible materials utilizing EPDM or FPM O-rings and seals with TFE seats. Valves shall be manufactured and supplied by Georg Fischer Piping Systems, Little Rock, AR.

Installation: Installation and testing shall be in accordance with accepted engineering and installation practices as noted in the Georg Fischer Piping Systems Technical Manual as well as the solvent cement manufacturer’s written in-structions. To ensure compatibility, all pipe, valves and fittings shall be manufactured and supplied by Georg Fischer Piping Systems.

******** CAUTION ******** Do not test with Air or Air over Water.

42

PVC IPS Schedule 40/80 Socket Dimensions

Size Pipe O.D.Entrance (A) Bottom (B)

Max. out of round

Schedule 40 socket depth (C) (min.)

Schedule 80 socket depth (C) (min).

Max. Min. Max. Min.

¼ 0.540 0.556 0.548 0.540 0.532 0.016 0.500 0.625

³/8 0.675 0.691 0.683 0.675 0.667 0.016 0.594 0.750

½ 0.840 0.852 0.844 0.840 0.832 0.016 0.688 0.875

¾ 1.050 1.062 1.054 1.050 1.042 0.020 0.719 1.000

1 1.315 1.330 1.320 1.315 1.305 0.020 0.875 1.125

1¼ 1.660 1.675 1.665 1.660 1.650 0.024 0.938 1.250

1½ 1.900 1.918 1.906 1.900 1.888 0.024 1.094 1.375

2 2.375 2.393 2.381 2.375 2.363 0.024 1.156 1.500

2½ 2.875 2.896 2.882 2.875 2.861 0.030 1.750 1.750

3 3.500 3.524 3.508 3.500 3.484 0.030 1.875 1.875

3½ 4.000 4.024 4.008 4.000 3.984 0.030 2.000

4 4.500 4.527 4.509 4.500 4.482 0.030 2.000 2.250

5 5.563 5.593 5.573 5.563 5.543 0.060 3.000

6 6.625 6.658 6.636 6.625 6.603 0.060 3.000 3.000

8 8.625 8.670 8.640 8.625 8.595 0.090 4.000 4.000

10 10.750 10.795 10.765 10.750 10.720 0.100 5.000 5.000

12 12.750 12.795 12.765 12.750 12.720 0.120 6.000 6.000

43

The melted plastic material is introduced to the mold and starts to flow around the core. Notice how the material tends to flow fairly evenly.

The plastic will continue to flow around the core.

As the material flows together, a knit line starts to form.This knit line is fairly obvious at this point in the molding process.

However, as the mold cavity starts to fill, the material tends to flow together and the knit lines become less obvious.

When the mold is completely full, the knit lines are still there, as they are part of the process. This is just how the part is manufactured.

Weld Lines (Knit Lines) in Molded Fittings

Injection molding is the forcing of a viscous material, under pressure, to fill a space, forming a part. In the injection molding of fittings there are two basic components, a mold, which forms the outside of the part, and a core, which forms the inside of the part. The injection molding process forces the molten plastic material into this interstitial space where the material is cooled and then released. Inherent in this process, for most geometries, is the flowing together of the material and the development of a weld line.

The point where the plastic material is forced into the mold is termed the gate. The plastic material flows through this gate, and when it hits the core it will flow around it in both directions. At the point where the material flows back together there will usually be a line, termed a weld line or a knit line. This point of the material flowing back together is usually located about 180˚ from the gate and, since the weld line is visible on both the OD and ID, it can sometimes be thought to be a crack.

This knit line is a surface phenomenon and does not indicate a weakness or a defect in the part. Fittings are subject to some significant pressure tests, using ASTM Specifications, assuring the user of a quality molded component.

44

Conversion ChartsDecimal and Millimeter Equivalents of Fractions

Inches Milli-meters

Inches Milli-meters

Inches Milli-meters

Inches Milli-metersFractions Decimals Fractions Decimals Fractions Decimals Fractions Decimals

1/64 .015625 .397 17/64 .265625 6.747 33/64 .515625 13.097 49/64 .765625 19.447

1/32 .03125 .794 9/32 .28125 7.144 17/32 .53125 13.494 25/32 .78125 19.844

3/64 .046875 1.191 19/64 .296875 7.541 35/64 .546875 13.891 51/64 .796875 20.241

1/16 .0625 1.588 5/16 .3125 7.938 9/16 .5625 14.288 13/16 .8125 20.638

5/64 .078125 1.984 21/64 .328125 8.334 37/64 .578125 14.684 53/64 .828125 21.034

3/32 .09375 2.381 11/32 .34375 8.731 19/32 .59375 15.081 27/32 .83475 21.431

7/64 .109375 2.778 23/64 .359375 9.128 39/64 .609375 15.478 55/64 .859375 21.828

1/8 .125 3.175 3/8 .375 9.525 5/8 .625 15.875 7/8 .875 22.225

9/64 .140625 3.572 25/64 .390625 9.922 41/64 .640625 16.272 57/64 .890625 22.622

5/32 .15625 3.969 13/32 .40625 10.319 21/32 .65625 16.669 29/32 .90625 23.019

11/64 .171875 4.366 27/64 .421875 10.716 43/64 .671875 17.066 59/64 .921875 23.416

3/16 .1875 4.763 7/16 .4375 11.113 11/16 .6875 17.463 15/16 .9375 23.813

13/64 .203125 5.159 29/64 .453125 11.509 45/64 .703125 17.859 61/64 .953125 24.209

7/32 .21875 5.556 15/32 .46875 11.906 23/32 .71875 18.256 31/32 .96875 24.606

15/64 .23475 5.953 31/64 .484375 12.303 47/64 .734375 18.653 63/64 .984375 25.003

1/4 .250 6.350 1/2 .500 12.700 3/4 .750 19.050 1 1.000 25.400

Length Conversion

Units of LengthMultiply units in left column by proper factor below

in. ft. yd. mile mm cm m km

1 inch 1 0.0833 0.0278 — 25.4 2.540 0.0254 —

1 foot 12 1 0.3333 — 304.8 30.48 0.3048 —

1 yard 36 3 1 — 914.4 91.44 0.9144 —

1 mile — 5280 1760 1 — — 1609.3 1.609

1 millimeter 0.0394 0.0033 — — 1 0.100 0.001 —

1 centimeter 0.3937 0.0328 0.0109 — 10 1 0.01 —

1 meter 39.37 3.281 1.094 — 1000 100 1 0.001

1 kilometer — 3281 1094 0.6214 — — 1000 1

(1 micron = 0.001 millimeter)

Weight Conversion

Units of WeightMultiply units in left column by proper factor below

grain oz. lb. ton gram kg metric ton

1 grain 1 — — — 0.0648 — —

1 ounce 437.5 1 0.0625 — 28.35 0.0283 —

1 pound 7000 16 1 0.0005 453.6 0.4536 —

1 ton — 32,000 2000 1 — 907.2

1 gram 15.43 0.0353 — — 1 0.001 —

1 kilogram — 35.27 2.205 — 1000 1

1 metric ton — 35,274 2205 1.1023 — 1000 1

45

Density Conversion

Units of DensityMultiply units in left column by proper factor below

lb./in.3 lb./ft.3 lb./gal. g/cm3 g/liter

1 pound/in.3 1 1728 231.0 27.68 27,680

1 pound/ft.3 — 1 0.1337 0.0160 16.019

1 pound/gal. 0.00433 7.481 1 0.1198 119.83

1 gram/cm3 0.0361 62.43 8.345 1 1000.0

1 gram/liter — 0.0624 0.00835 0.001 1

Area Conversion

Units of AreaMultiply units in left column by proper factor below

in.2 ft.2 acre mile2 cm2 m2 hectare

1 inch2 1 0.0069 — — 6.452 — —

1 foot2 144 1 — — 929.0 0.0929 —

1 acre — 43,560 1 0.0016 — 4047 0.4047

1 mile2 — — 640 1 — — 259.0

1 centimeter2 0.1550 — — — 1 0.0001 —

1 meter2 1550 10.76 — — 10,000 1 —

1 hectare — — 2.471 — 1 10,000 1

Volume Conversion

Units of VolumeMultiply units in left column by proper factor below

in.3 ft.3 yd.3 cm.3 meter3 liter U.S. gal. Imp. gal.

1 inch3 1 — — 16.387 — 0.0164 — —

1 foot3 1728 1 0.0370 28,317 0.0283 28.32 7.481 6.229

1 yard3 46,656 27 1 — 0.7646 764.5 202.0 168.2

1 centimeter 3 0.0610 — — 1 — 0.0010 — —

1 meter3 61,023 35.31 1.308 1,000,000 1 999.97 264.2 220.0

1 liter 61.025 0.0353 — 1000.028 0.0010 1 0.2642 0.2200

1 U.S. gallon 231 0.1337 — 3785.4 — 3.785 1 0.8327

1 Imp. gallon 277.4 0.1605 — 4546.1 — 4.546 1.201 1

Pressure Conversion

Units of Pressure

Multiply units in left column by proper factor below

lbs./in.2 lb./ft.2 Int. etc. kg/cm2 mm Hg at 32°F

in. Hg at 32°F

ft. water at 39.2°F

kPa

lb./in.2 1 144 - 0.0703 51.713 2.0359 2.307 6.894

lb./ft.2 0.00694 1 - - 0.3591 0.01414 0.01602 0.04788

Int. etc. 14.696 2116.2 1 1.0333 760 29.921 33.90 -

kg/cm2 14.223 2048.1 0.9678 1 735.56 28.958 32.81 98.066

mm Hg 0.0193 2.785 - - 1 0.0394 0.0446 0.1333

in Hg 0.4912 70.73 0.0334 0.0345 25.400 1 1.133 3.386

ft H20 0.4335 62.42 - 0.0305 22.418 0.8826 1 2.988

kPa 0.00145 20.89 - 0.010169 7.5006 0.2953 0.3346 1

46

Temperature Conversion

°F °C °F °C °F °C °F °C °F °C-459.4 -273 1 -17.2 61 16.1 300 149 900 482-450 -268 2 -16.7 62 16.7 310 154 910 488-440 -262 3 -16.1 63 17.2 320 160 920 493-430 -257 4 -15.6 64 17.8 330 166 930 499-420 -251 5 -15 65 18.3 340 171 940 504-410 -246 6 -14.4 66 18.9 350 177 950 510-400 -240 7 -13.9 67 19.4 360 182 960 516-390 -234 8 -13.3 68 20 370 188 970 521-380 -229 9 -12.8 69 20.6 380 193 980 527-370 -223 10 -12.2 70 21.1 390 199 990 532-360 -218 11 -11.7 71 21.7 400 204 1000 538-350 -212 12 -11.1 72 22.2 410 210 1020 549-340 -207 13 -10.6 73 22.8 420 215 1040 560-330 -201 14 -10 74 23.3 430 221 1060 571-320 -196 15 -9.4 75 23.9 440 227 1080 582-310 -190 16 -8.9 76 24.4 450 232 1100 593-300 -184 17 -8.3 77 25 460 238 1120 604-290 -179 18 -7.8 78 25.6 470 243 1140 616-280 -173 19 -7.2 79 26.1 480 249 1160 627-273 -169 20 -6.7 80 26.7 490 254 1180 638-270 -168 21 -6.1 81 27.2 500 260 1200 649-260 -162 22 -5.6 82 27.8 510 266 1220 660-250 -157 23 -5 83 28.3 520 271 1240 671-240 -151 24 -4.4 84 28.9 530 277 1260 682-230 -146 25 -3.9 85 29.4 540 282 1280 693-220 -140 26 -3.3 86 30 550 288 1300 704-210 -134 27 -2.8 87 30.6 560 293 1350 732-200 -129 28 -2.2 88 31.1 570 299 1400 760-190 -123 29 -1.7 89 31.7 580 304 1450 788-180 -118 30 -1.1 90 32.2 590 310 1500 816-170 -112 31 -0.6 91 32.8 600 316 1550 843-160 -107 32 0 92 33.3 610 321 1600 871-150 -101 33 0.6 93 33.9 620 327 1650 899-140 -96 34 1.1 94 34.4 630 332 1700 927-130 -90 35 1.7 95 35 640 338 1750 954-120 -84 36 2.2 96 35.6 650 343 1800 982-110 -79 37 2.8 97 36.1 660 349 1850 1010-100 -73 38 3.3 98 36.7 670 354 1900 1038

-90 -68 39 3.9 99 37.2 680 360 1950 1066-80 -62 40 4.4 100 37.8 690 366 2000 1093-70 -57 41 5 110 43 700 371 2050 1121-60 -51 42 5.6 120 49 710 377 2100 1149-50 -46 43 6.1 130 54 720 382 2150 1177-40 -40 44 6.7 140 60 730 388 2200 1204-30 -34 45 7.2 150 66 740 393 2250 1232-20 -29 46 7.8 160 71 750 399 2300 1260-10 -23 47 8.3 170 77 760 404 2350 1288

0 -17.8 48 8.9 180 82 770 410 2400 131649 9.4 190 88 780 416 2450 134350 10 200 92 790 421 2500 137151 10.6 210 99 800 427 2550 139952 11.1 212 100 810 432 2600 142753 11.7 220 104 820 438 2650 145454 12.2 230 110 830 443 2700 148255 12.8 240 116 840 449 2750 151056 13.3 250 121 850 454 2800 153857 13.9 260 127 860 460 2850 156658 14.4 270 132 870 466 2900 159359 15 280 138 880 471 2950 162160 15.6 290 143 890 477 3000 1649

Item #469 (1/07)© George Fischer, Inc. 2007Printed in USA

AustraliaGeorge Fischer Pty LtdKingsgrove NSW 2008Phone +61(0)2-9554 3977australia.ps@georgfischer.comwww.georgefischer.com.au

AustriaGeorg Fischer Rohrleitungssysteme GmbH3130 HerzogenburgPhone +43(0)2782-856 430austria.ps@georgfischer.comwww.georgfischer.at

Belgium / LuxembourgGeorg Fischer NV/SA1070 Bruxelles/BrüsselPhone +32(0)2-556 40 20be.ps@georgfischer.comwww.georgfischer.be

BrazilGeorge Fischer Ltda04795-100 São PauloPhone +55(0)11-5687 1311br.ps@georgfischer.comwww.georgefischer.com.br

ChinaGeorg Fischer Piping Systems Ltd Shanghai Pudong, Shanghai 201319Phone +86(0)21-5813 3333 china.ps@georgfischer.comwww.cn.piping.georgfischer.com

Denmark / IcelandGeorg Fischer A/S2630 TaastrupPhone +45 (0)70 22 19 75info.dk.ps@georgfischer.comwww.georgfischer.dk

FranceGeorge Fischer S.A.S.93208 Saint-Denis Cedex 1Phone +33(0)1-492 21 34 1fr.ps@georgfischer.comwww.georgefischer.fr

GermanyGeorg Fischer GmbH73095 Albershausen Phone +49(0)7161-302-0info.de.ps@georgfischer.comwww.rls.georgfischer.de

Georg Fischer DEKA GmbH35232 Dautphetal-MornshausenPhone +49(0)6468-915-0deka.ps@georgfischer.comwww.dekapipe.de

GreeceGeorg Fischer S.p.A.10434 Athens Phone +30(0)1/882 04 91office@piping-georgfischer.gr

IndiaGeorge Fischer Piping Systems Ltd400 093 MumbaiPhone +91(0)22-2821 7749in.ps@georgfischer.com

ItalyGeorg Fischer S.p.A.20063 Cernusco S/N (MI)Phone +39 02-921 861it.ps@georgfischer.comwww.georgfischer.it

JapanGeorg Fischer Ltd556-0011 OsakaPhone +81(0)6-6635 2691jp.ps@georgfischer.comwww.georgfischer.jp

MalaysiaGeorg Fischer (M) Sdn. Bhd.47500 Subang JayaPhone +603-8024 7879conne.kong@georgefischer.com.my

NetherlandsGeorg Fischer N.V.8161 PA EpePhone +31(0)578-678 222 nl.ps@georgfischer.comwww.georgfischer.nl

NorwayGeorg Fischer AS1351 Rud Phone +47 67 18 29 00no.ps@georgfischer.comwww.georgfischer.no

PolandGeorg Fischer Sp. z o.o.02-226 Warszawa Phone +48(0)22-313 10 50 poland.ps@georgfischer.comwww.georgfischer.pl

RomaniaGeorg Fischer Rohrleitungssysteme AG70000 Bucharest - Sector 1Phone +40(0)21-222 91 36ro.ps@georgfischer.com

SingaporeGeorge Fischer Pte Ltd417 845 SingaporePhone +65(0)67-47 06 11sgp.ps@georgfischer.comwww.georgefischer.com.sg

Spain / PortugalGeorg Fischer S.A.28009 MadridPhone +34(0)91-781 98 90es.ps@georgfischer.comwww.georgfischer.es

Sweden / FinlandGeorg Fischer AB12523 Älvsjö-StockholmPhone +46(0)8-506 775 00se.ps@georgfischer.comwww.georgfischer.se

SwitzerlandGeorg Fischer Rohrleitungssysteme (Schweiz) AG8201 SchaffhausenPhone +41(0)52-631 30 26ch.ps@georgfischer.comwww.piping.georgfischer.ch

United Kingdom / IrelandGeorge Fischer Sales LimitedCoventry, CV2 2STPhone +44(0)2476 535 535uk.ps@georgfischer.comwww.georgefischer.co.uk

USA / Canada / Latin America / CarribeanGeorge Fischer Inc.Tustin, CA 92780-7258Phone (714) 731-8800, Toll Free (800) 854-4090us.ps@georgfischer.comwww.gfpiping.com

7777 Sloane Drive, Little Rock, AR 72206 Tel. (501) 490-7777, Toll Free (800) 423-2686 Fax (501) 490-7100 e-mail: sloane.ps@georgfischer.comwww.gfpiping.com

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